Air system

ABSTRACT

A grain handling system having an air system is presented that is capable of automatically detecting and clearing a plug in a tube of an air system using a central controller, an air pressure sensor, a dynamic pressure relief valve and a variable frequency drive connected to and controlling a blower motor. When a plug is detected, the central controller stops the flow of grain into the tube and ramps up the output of the blower motor to full capacity. Thereafter, the central controller performs an unplugging routine by opening and closing the dynamic pressure relief valve causing surges of air to impact the plug either breaking up the plug or bumping the plug along the tube until it clears. Once the plug clears, the central controller resumes normal operation.

CROSS REFERENCE TO RELATED APPLICATIONS

This utility patent application claims priority to U.S. ProvisionalPatent Application No. 62/781,718 filed on Dec. 19, 2018 entitled “AirSystem” which is fully incorporated by reference herein.

FIELD OF THE ART

This disclosure relates to the material handling arts. Morespecifically, and without limitation, this disclosure relates to grainhandling arts.

BACKGROUND

Since the development of harvesting technology that is capable ofseparating the desired grains from the surrounding chaff, newtechnologies have been developed to handle bulk quantities of grain.That is, new technologies have been developed to store bulk grain, suchas grain bins; new technologies have been developed to dry grain, suchas grain dryers; and new technologies have been developed to move grain,such as bucket elevators, drag chains, belt systems and air systems, toname a few.

One common form of a grain handling system is known as an air system.Air systems are used to move grain from a source of grain to a storagedevice or other device by flowing pressurized air through a tube whilegrain is also injected into the tube.

Air systems have many advantages. That is, air systems are relativelyinexpensive. Air systems have relatively few moving parts. Air systemscan be used to transport grain to a number of storage devices in arelatively easy manner. Air systems are highly adaptable and can be usedin a great variety of applications. Air systems are relatively easy toinstall and maintain. These are only a few of the many other advantagesto using air systems to transport grain.

While air systems have many advantages, air systems suffer from a numberof challenges. That is, as air systems are dependent upon flowing air tomove grain through a tube, changes in the air, such as temperature,humidity, barometric pressure, and the like can affect the performanceof an air system. In addition, air systems are sensitive to changes inthe grain flowing through the tube, such as changes in weight, changesin size, changes in moisture content, changes in debris or finescontent, and the like, which can affect the operation of an air system.In addition, air systems are sensitive to the speed at which grain isadded to the air system, among countless other variables.

This sensitivity means that an air system that is optimally performingone moment can be woefully out of tune and prone to plugging shortlythereafter. As such, existing air systems require constant manualoversight to ensure they are operating properly otherwise they candamage the grain by moving it too fast through the tubing oralternatively the air system can plug.

When an air system plugs, this is a significant problem. When an airsystem plugs the air system requires immediate attention and immediateactions must be taken otherwise parts can break and/or the plug can getirreparably worse. Namely, when a plug is detected, the flow of graininto the tube must be immediately stopped, otherwise the added grainwill make the plug worse. In addition, when a plug is detectedprecautionary measures must be taken to ensure the blower motor and/orother components do not overload and burn out. When a plug occurs in anair system, manual maintenance is required to clear the plug beforenormal operation of the grain handling system can resume. This isobviously undesirable and time consuming, especially during the pressureof harvest time.

Therefore, for all the reasons stated above, and the reasons statedbelow, there is a need in the art for an improved air system.

Thus, it is an object of at least one embodiment to provide an airsystem and method of control that improves upon the state of the art.

Another object of at least one embodiment is to provide an air systemand method of control that reduces plugging of the air system.

Yet another object of at least one embodiment is to provide an airsystem and method of control that automatically detects plugging of theair system.

Another object of at least one embodiment is to provide an air systemand method of control that automatically clears plugs in the air system.

Yet another object of at least one embodiment is to provide an airsystem and method of control that automatically detects plugs in the airsystem

Another object of at least one embodiment is to provide an air systemand method of control that automatically shuts down the flow of graininto the air system when a plug is detected.

Yet another object of at least one embodiment is to provide an airsystem and method of control that minimizes a plug in the air systemwhen the plug is detected.

Another object of at least one embodiment is to provide an air systemand method of control that is capable of clearing a plug and resumingnormal operation automatically and without manual intervention.

Yet another object of at least one embodiment is to provide an airsystem and method of control that that is more robust than existing airsystems.

Another object of at least one embodiment is to provide an air systemand method of control that that reduces the cost of operating airsystems.

Yet another object of at least one embodiment is to provide an airsystem and method of control that that reduces the labor related tooperating air systems

Another object of at least one embodiment is to provide an air systemand method of control that that makes air systems more desirable.

Yet another object of at least one embodiment is to provide an airsystem and method of control that that optimally controls operation ofthe air system.

Another object of at least one embodiment is to provide an air systemand method of control that reduces the potential for catastrophicoccurrences.

Yet another object of at least one embodiment is to provide an airsystem and method of control that that increases the up-time of airsystems.

Another object of at least one embodiment is to provide an air systemand method of control that reduces the down-time of air systems.

Yet another object of at least one embodiment is to provide an airsystem and method of control that provides new functionality for airsystems

Another object of at least one embodiment is to provide an air systemand method of control that improves the safety of using air systems.

Yet another object of at least one embodiment is to provide an airsystem and method of control that is easy to use.

Another object of at least one embodiment is to provide an air systemand method of control that has a robust design.

Yet another object of at least one embodiment is to provide an airsystem and method of control that works effectively.

Another object of at least one embodiment is to provide an air systemand method of control that saves time.

Yet another object of at least one embodiment is to provide an airsystem and method of control that is efficient to use.

Another object of at least one embodiment is to provide an air systemand method of control that has a long useful life.

Yet another object of at least one embodiment is to provide an airsystem and method of control that protects the quality of the grain.

Another object of at least one embodiment is to provide an air systemand method of control that is durable.

Yet another object of at least one embodiment is to provide an airsystem and method of control that is relatively inexpensive.

Another object of at least one embodiment is to provide an air systemand method of control that is high quality.

Yet another object of at least one embodiment is to provide an airsystem and method of control that can be used with practically any grainhandling system.

Another object of at least one embodiment is to provide an air systemand method of control that makes it easier to handle grain.

These and other objects, features, or advantages of at least oneembodiment will become apparent from the specification, figures andclaims.

SUMMARY

A grain handling system having an air system is presented that iscapable of automatically detecting and clearing a plug in a tube of anair system using a central controller, an air pressure sensor, a dynamicpressure relief valve and a variable frequency drive connected to andcontrolling a blower motor. When a plug is detected, the centralcontroller stops the flow of grain into the tube and ramps up the outputof the blower motor to full capacity. Thereafter, the central controllerperforms an unplugging routine by opening and closing the dynamicpressure relief valve causing surges of air to impact the plug eitherbreaking up the plug or bumping the plug along the tube until it clears.Once the plug clears, the central controller resumes normal operation.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a grain handling system having a wet bin, aninput device, a grain dryer, an air system and a dry bin;

FIG. 2 is a close up perspective cut-away view of the grain dryer ofFIG. 1 , the view showing added details of the grain dryer;

FIG. 3 is an elevation section view of the end of a gain dryer similarto that shown in FIGS. 1 and 2 , the view showing added details of thegrain dryer;

FIG. 4 is a close up plan view of the air system of FIG. 1 used inassociation with the central controller and other components of thesystem;

FIG. 5 is a plan view of a demonstrative chart showing air pressure innormal operation as well as when a plug occurs;

FIG. 6 is a plan view of a demonstrative chart showing current draw of ablower motor in normal operation as well as when a plug occurs;

FIG. 7 is a plan view of a demonstrative chart showing unload motorspeed in normal operation as well as when a plug is detected;

FIG. 8 is a plan view of a demonstrative chart showing operation of avariable frequency drive which operates a blower motor in normaloperation as well as when a plug occurs and an unplugging routine isimplemented;

FIG. 9 is a plan view of a demonstrative chart showing air pressureduring an unplugging routine as well as when a plug is cleared;

FIG. 10A is a plan view of a chart;

FIG. 10B is a sequence of steps of a typical startup sequence of thegrain handling system having a central controller, a grain dryer and anair system;

FIG. 11A is a plan view of a chart;

FIG. 11B is a sequence of steps of a typical automated operationsequence of the grain handling system having a central controller, agrain dryer and an air system, the view showing variations of theconfiguration of the system and how they may be controlled;

FIG. 12A is a plan view of a chart;

FIG. 12B is a sequence of steps of a typical automated unpluggingoperation and sequence of the grain handling system having a centralcontroller, a grain dryer and an air system, an dynamic pressure reliefvalve, and a variable frequency drive, the view also showing steps forsetting grain dryer unload air system maximum operation interlock;

FIG. 12C is a continuation of FIG. 12A and FIG. 12B, and is a sequenceof steps of a dryer unload air system maximum operation interlock whichis a procedure that will control the dryer in order to maximize thethroughput of the air system;

FIG. 12D is a sequence of steps of an air system automated limit finderwhich is a procedure that will inform the dryer of the limits of the airsystem.

DETAILED DESCRIPTION

In the following detailed description, reference is made to theaccompanying drawings which form a part hereof, and in which is shown byway of illustration specific embodiments in which various embodiments ofthe disclosure may be practiced. These embodiments are described insufficient detail to enable those skilled in the art to practice thedisclosure, and it is to be understood that other embodiments may beutilized and that mechanical, procedural, and other changes may be madewithout departing from the spirit and scope of the disclosure. Thefollowing detailed description is, therefore, not to be taken in alimiting sense, and the scope is defined only by the appended claims,along with the full scope of equivalents to which such claims areentitled.

As used herein, the terminology such as vertical, horizontal, top,bottom, front, back, end, sides, left, right, and the like arereferenced according to the views, pieces, parts, components and figurespresented. It should be understood, however, that the terms are usedonly for purposes of description, and are not intended to be used aslimitations. Accordingly, orientation of an object or a combination ofobjects may change without departing from the scope of the disclosure.

System:

With reference to the figures, a grain handling system 10 (or system 10)is presented. The grain handling system 10 is shown in use with a wetgrain bin 12 that stores grain 14 (wet grain), an input device 16, agrain dryer 18, an air system 20, a dry grain bin 22 that receives grain14 (dry grain) and a central controller 24 that is connected through theinternet 26, the cloud 28 and/or a wired and/or a wireless network 30 toa user's electronic device 32 such as a computer 34, a cell phone 36and/or a tablet 38 among other parts and components described furtherherein.

In the example shown in FIG. 1 , grain handling system 10 is shown anddescribed in what is known as a drying operation which is oftenperformed at or around the time of harvest where grain 14 is harvestedwith a moisture content that is higher than what is acceptable for longterm storage. This wet grain 14 then must be dried before it can bestored for extended periods of time without spoilage. In this example,of FIG. 1 , when harvested, wet grain 14 is stored in wet grain bin 12while it waits to be dried using grain dryer 18. This wet grain 14 istransported out of wet grain bin 12 through input device 16 and intograin dryer 18. The wet grain 14 passes through grain dryer 18 whilebeing exposed to heat and air movement which reduces the moisturecontent of the grain 14 to an acceptable level for long term storage.This dry grain 14 exits the dryer 18 and moves through tube 40 by airmovement forced through tube 40 by air system 20. This dry grain 14 isthen deposited in dry grain bin 22 where it may be stored for extendedperiods of time without spoilage.

This example of a drying operation is only that, an example. This dryingoperation is only one of countless ways that grain handling system 10and air system 20 may be used to store, move, dry, mix, deliver andotherwise handle grain 14. As such, description of grain handling system10 and air system 20 in association with a drying operation is not meantto be limiting. Instead, description of grain handling system 10 and airsystem 20 in association with a drying operation is only intended toserve as one way of describing how the grain handling system 10 and airsystem 20 operate. It is hereby contemplated that the teachings of thisdisclosure are intended to apply to all ways in which grain handlingsystem 10 and air system 20 may be used to handle grain 14.

In addition, while the grain handling system 10 and air system 20 aredescribed herein in association with the handling of grain 14, grainhandling system 10 and air system 20 is not limited to use with grain14. Instead, it is hereby contemplated that grain handling system 10 andair system 20 may be used with any flowable material and/or particulatematerial without limitation. Description of the use of grain handlingsystem 10 and air system 20 in association with grain 14 is only one ofcountless examples of use.

Wet Grain Bin:

In the arrangement shown, as one example, grain handling system 10 isused in association with what is known as a wet grain bin 12. Wet grainbin 14 is formed of any suitable size, shape and design and isconfigured to store bulk wet grain 14 that is to be dried using graindryer 18. In the arrangement shown, as one example, wet grain bin 12 isa large, generally cylindrical structure that has a curved sidewall 42.Sidewall 42 connects at its lower end to a foundation 44. Sidewall 42connects at its upper end to a peaked roof 46.

Sidewall 42 of wet grain bin 12 is formed of any suitable size, shapeand design. In one arrangement, as is shown, sidewall 42 is formed of aplurality of sheets 48 of material that are connected to one another inoverlapping edge-to-edge alignment. In the arrangement shown, thesesheets 48 are assembled in rings 50 that are stacked on top of oneanother between foundation 44 and roof 46. In the arrangement shown, asone example, to provide additional strength and rigidity, sheets 48 ofsidewall 42 include corrugated undulations therein. Also, in thearrangement shown, as one example, the exterior surface of sidewall 42include stiffeners 52 that extend from foundation 44 to roof 46 whichprovide further structural rigidity to wet grain bin 12.

In the arrangement shown, as one example, wet grain bin 12 includes anopening 54 at the approximate center of roof 46 through which grain 14is added to wet grain bin 12. In the arrangement shown, as one example,wet grain bin 12 includes an opening 56 at its lower end through whichgrain 14 is removed from wet grain bin 12.

Wet grain bin 12 serves as a source of grain 14 for grain handlingsystem 10, grain dryer 18 and air system 20. While wet gain bin 12 isshown and described, any other storage device is hereby contemplated foruse as a source of grain 14 for system 10 such as a silo, a pit, or anyother form of a grain storage device or system.

In the arrangement shown, as one example, grain 14 is removed from wetgrain bin 12 through opening 56 input device 16 which delivers grain 14to grain dryer 18.

Dry Grain Bin:

In the arrangement shown, as one example, grain handling system 10 isused in association with dry grain bin 22. The disclosure providedherein with respect to wet grain bin 12 applies to dry grain bin 22. Assuch for purposes of brevity, unless stated otherwise, disclosurerelated to wet grain bin 12 is equally applicable to dry grain bin 22.

In the arrangement shown, as one example, grain 14 is received throughopening 54 at the upper end of dry grain bin 22 from tube 40 by way ofair pressure and air flow from air system 20.

Input Device:

In the arrangement shown, as one example, grain handling system 10 isused in association with input device 16. Input device 16 is formed ofany suitable size, shape and design and is configured to move grain 14from wet grain bin 12 to grain dryer 18. In the arrangement shown, asone example, input device 16 connects to opening 56 in the lower end ofwet grain bin 12 and drains grain 14 out of wet grain bin 12.

In the arrangement shown, as one example, input device 16 is formed ofan auger 58 having helical fighting 60 that rotate within a cylindricalshield 62 under the power of motor 64. In one arrangement, auger 58connects to a sump positioned in the floor of the wet grain bin 12 whichis covered by a gate. When the gate is opened and the auger 58 isoperated by motor 64 such that helical flighting 60 rotates withinshield 62 grain 14 is carried out of wet grain bin 12 through inputdevice 16 to grain dryer 18.

While an auger 58 system is shown in use as input device 16, any othermanner, method or means or apparatus is hereby contemplated for use toconvey wet grain 14 from wet grain bin 12, or another source of grain14, to grain dryer 18.

Grain Dryer:

In the arrangement shown, as one example, grain handling system 10 isused in association with a grain dryer 18. Grain dryer 18 is formed ofany suitable size, shape and design and is configured to reduce themoisture content of grain 14. In the arrangement shown, as one example,grain dryer 18 is what is known as a continuous flow grain dryer 18 or across-flow grain dryer. However any other form of a grain dryer 18 ishereby contemplated for use.

Continuous flow grain dryer 18 operates by receiving wet grain 14 at atop side. This wet grain 14 travels by the force of gravity downwardthrough the grain dryer 18 as it is conditioned by air blowing throughthe grain 14. By the time the grain 14 reaches the bottom side of thegrain dryer 18 the grain 14 has been dried to the desire moisturecontent. This dried grain 14 is discharged at a bottom side of the graindryer 18.

In the arrangement shown, as one example, grain dryer 18 includes aninput 66 at its top side that is configured to receive wet grain 14 fromthe output end of input device 16. This wet grain 14 is then distributedevenly across grain dryer 18 by loading system 68. In the arrangementshown, as one example, loading system 68 is formed of an auger systemthat dispenses grain 14 across the top side of the grain dryer 18.However any other grain moving device or system is hereby contemplatedfor use as loading system 68.

In the arrangement shown, as one example, wet grain 14 loaded into graindryer 18 travels downward on either side of the loading system 68 underthe force of gravity between an interior wall 70 and an exterior wall72. The space between the interior wall 70 and the exterior wall 72 isknown as the grain column 74. Interior wall 70 and exterior wall 72 areperforated so as to allow air to flow through the interior wall 70 andthe exterior wall 72 while retaining the grain 14 within the graincolumn 74. These perforations in interior wall 70 and exterior wall 72allow air to pass through the grain. These perforations in interior wall70 and exterior wall 72 also allow fines to pass through the interiorwall 70 and exterior wall 72 which can accumulate on the exteriorsurface of the exterior wall 72 when air is being blown outward throughthe grain column 74 and which can accumulate on the interior surfaceand/or within the plenum 76 when air is sucked through the grain column74 and into plenum 76.

In the arrangement shown, as one example, plenum 76 is formed betweenthe interior surfaces of opposing interior walls 70. In the arrangementshown, as one example, plenum 76 is the hollow interior within graindryer 18. Plenum 76 facilitates air movement through the grain columns74.

In the arrangement shown as one example in FIGS. 1 and 2 , grain dryer18 is a heat only grain dryer. That is, the plenum 76 is a single,continuous and undivided space within grain dryer 18 that receivesheated air blown into plenum 76 from the heater and fan system 78. Thisheated air then passes outward through the perforated interior wall 70,through the grain 14 within grain column 74, and out the perforatedexterior wall 72. In this way, grain 14 within grain column 74 is heatedand moisture is expelled from the grain 14 thereby drying the grain 14.

In an alternative arrangement, plenum 76 is divided into a heat sectionand a cool section by a divider. In one arrangement the heater and fansystem 78 is positioned at or in the divider between the heat sectionand cool section such that air is blown from the cool section into theheat section. That is, the heat section of plenum 76 is pressurized andreceives heated air from heater and fan system 78 that is blown outwardthrough the perforated interior wall 70, through the grain 14 withingrain column 74, and out the perforated exterior wall 72. In contrast,the cool section is under vacuum and receives air that is sucked inwardthrough the perforated exterior wall 72, through the grain 14 within thegrain column 74, and through the perforated interior wall 70 into thecool section of plenum 76. The addition of a cool section provides thebenefit of sucking air into the plenum 76 through heated grain 14 in thegrain column 74. This provides the benefit of heating or preheating theair by pulling it through the heated grain 14 in the grain column 74.This is also known as preserving this heat or recycling this heat orconservation of energy. This conservation of energy provides energysavings as the air is heated somewhat as it is pulled into the plenum76. Then, this pre-heated air is heated further through the burner ofthe heater and fan system 78. But, due to the pre-heating of the air,the heater and fan system 78 does not have to raise the temperature ofthis air as far as it otherwise would without the pre-heating therebyproviding energy savings.

When grain 14 reaches the end of grain column 74 it is metered out ofgrain column 74 by metering system 80.

Metering System: Metering system 80 is formed of any suitable size,shape and design and is configured to meter grain 14 out of the graincolumn 74 at adjustable desired rates. In the arrangement shown, as oneexample, metering system 80 is positioned at, adjacent or near the lowerend of grain column 74. That is, in the arrangement shown, meteringsystem 80 is positioned at, adjacent or near the lower end of interiorwall 70 and the lower end of exterior wall 72 and is configured to metergrain 14 out of grain column 74. The grain 14 metered out of graincolumn 74 falls by the force of gravity into the discharge system 82.

In the arrangement shown, as one example, metering system 80 is formedof an interior metering roll 84 positioned at, adjacent or near thelower end of interior wall 70 and an exterior metering roll 86positioned at, adjacent or near the lower end of exterior wall 72.However, any number of metering rolls are hereby contemplated for use,such as one, two, three, four, five or more.

In the arrangement shown, as one example, with an interior metering roll84 positioned adjacent the interior wall 70 and a exterior metering roll86 positioned adjacent the exterior wall 72 this provides the benefit ofmetering out different portions of the grain column 74 at differentrates or speeds or amounts. That is, due to heated air being blownoutward from plenum 76, the grain 14 within grain column 74 adjacentinterior wall 70 tends to heat faster, and dry quicker, as it is closerto the heat source. In contrast, the grain 14 within grain column 74adjacent exterior wall 72 tends to heat slower, and take longer to dry,as it is further from the heat source.

By having an interior metering roll 84 and an exterior metering roll 86this allows for grain 14 within different portions of the grain column74 to be metered at different rates as well as being discharged atdifferent positions. That is, the interior metering roll 84 may beoperated to dispense the grain 14 that is heated the fastest at a highermetering rate so as to not over-dry the grain 14 in the interior portionof the grain column 74. In contrast, the exterior metering roll 86 maybe operated to dispense the grain 14 that is heated slower at a lowermetering rate so as to allow this grain 14 adequate time within thegrain column 74 to sufficiently dry. In addition, in one arrangement theinterior metering roll 84 is positioned slightly above the exteriormetering roll 86. By placing the interior metering roll 84 above theexterior metering roll 86 this allows for grain 14 adjacent the interiorwall 70 to be discharged sooner than grain 14 adjacent the exterior wall72. As such, providing an interior metering roll 84 and an exteriormetering roll 86 in the grain column 74 allows for more precise controlof the grain drying process and provides more even drying results.

To properly guide grain toward the interior metering roll 84 and theexterior metering roll 86, an interior guide 88 and an exterior guide 90are positioned within grain column 74. Interior guide 88 and exteriorguide 90 are formed of any suitable size, shape and design. In thearrangement shown, as one example, interior guide 88 angles from theinterior wall 70 to interior metering roll 84 and exterior guide 90angles from a mid-region of grain column 74 to exterior metering roll86. In this way, interior guide 88 and exterior guide 90 separate graincolumn 74 into two streams of grain, an interior stream and an exteriorstream. These independent interior stream and exterior stream of grain14 are independently metered by interior metering roll 84 and exteriormetering roll 86.

In an alternative arrangement, only a single metering roll is used.

Interior metering roll 84 and exterior metering roll 86 are formed ofany suitable size, shape and design and serve to meter grain out ofgrain column 74. In the arrangement shown, interior metering roll 84 andexterior metering roll 86 are formed of approximately the same size,shape and design and include an elongated axle 92 with a plurality offlights 94 that are connected to axle 92 that extend along all or aportion of the length of axle 92. In the arrangement shown, as oneexample, four flights 94 are connected to axle 92 and extend outwardfrom axle 92. However any number of flights 94 is hereby contemplatedfor use. Axle 92 serves as the axis of rotation of interior meteringroll 84 and exterior metering roll 86 and as the axle 92 rotates eachflight 94 dispenses an amount of grain from the grain column 74 thatfalls by the force of gravity into the discharge system 82.

Discharge System: Discharge system 82 is formed of any suitable size,shape and design and is configured to discharge grain 14 metered out ofgrain column 74 by metering system 80 out of the grain dryer 18. In thearrangement shown, as one example, in FIG. 2 , discharge system 82 is anauger system. In another arrangement, as another example, in FIG. 3 ,discharge system 82 is what is known as a drag unload or a drag chain.However any other form of an unload system is hereby contemplated foruse as discharge system 82 such as a belt, an auger, or the like.

Discharge system 82 carries grain 14 to an outlet 96 at which pointgrain 14 discharged from grain dryer 18 is conveyed to air system 20 fortransport to dry grain bin 22.

Air System:

In the arrangement shown, as one example, system 10 is used inassociation with air system 20. Air system 20 is formed of any suitablesize, shape and design and is configured to facilitate thetransportation of grain 14 through the grain handling system 10 throughthe use of pressurized air blown through tube 40.

Air Input: In the arrangement shown, as one example, air system 20includes an air input 98. Air input is formed of any suitable size,shape and design and is configured to facilitate the entry of air intoair system 20. In the arrangement shown, air input 98 includes a filter100 positioned at a first end of a stack tube 102 that is connected at asecond end to a blower housing 104. Air input 98 facilitates the entryof air into air system 20 while filter 100 filters the air.

Blower, Blower Housing and Blower Motor: In the arrangement shown, asone example, air system 20 includes a blower 103 having a blower housing104 connected to a blower motor 106. Blower housing 104 is formed of anysuitable size, shape and design and is configured to pull air throughair input 98, or more specifically through filter 100 and stack tube102, and blow this air through tube 40. In the arrangement shown, as oneexample, blower housing 104 includes an exterior shell or housing thatcontains a fan or pump mechanism therein that causes the movement of airfrom air input 98 through tube 40. In the arrangement shown, as oneexample, blower housing 104 is connected to and operated by blower motor106. Blower motor 106 is formed of any suitable size, shape and designand is configured to facilitate operation of blower housing 104. In thearrangement shown, as one example, blower motor 106 is an electric motorthat is connected to a shaft of blower housing 104. In this arrangement,when blower motor 106 rotates so rotates the internal components ofblower housing 104. In one arrangement, the faster blower motor 106rotates the faster the internal components of blower housing 104 rotate.Or, said another way, the higher the output or faster the output ofblower motor 106 the higher the output or faster the output of blowerhousing 104. Any other device other than an electric motor is herebycontemplated for use as blower motor 106 such as a gas powered motor, asteam engine, a belt drive, a chain drive, a gear drive, or any othersource of power or rotational force. Also, while the blower motor 106and blower housing 104 are shown as separate but operably connectedcomponents, in another arrangement blower motor 106 and blower housing104 may be formed of a single integrated unit. Blower housing 104 andblower motor 106 operate in concert with one another to facilitate airflow through tube 40 and as such, reference to one of blower housing 104or blower motor 106 may refer to both blower housing 104 and blowermotor 106 and/or the collective effect of blower housing 104 and blowermotor 106 which is to blow pressurized air through tube 40. Also, whilea single blower motor 106 is shown, it is hereby contemplated that twoor more blower motors 106 may be used. Similarly, while a single blowerhousing 104 is shown, it is hereby contemplated that two or more blowerhousings 104 may be used.

In the arrangement shown, as one example, blower motor 106 iselectronically connected to and controlled by central controller 24, asis further described herein.

In the arrangement shown, as one example, the input side of blowerhousing 104 is connected to air input 98, which facilitates air flowinto blower housing 104. In the arrangement shown, as one example, theoutput side of blower housing 104 is connected to tube 40, whichreceives the pressurized air flow out of blower housing 104.

Tube: Tube 40 is formed of any suitable size, shape and design and isconfigured to receive pressurized air flow from blower housing 104. Inthe arrangement shown, as one example, tube 40 is a generallycylindrically shaped hollow tube that extends from end-to-end betweencomponents of the system 10 as is described herein. Tube 40 may beformed of a single continuous length or a plurality of connectedlengths. Where possible, tube 40 may extend in a straight manner, andwhere necessary tube 40 may bend, curve, split, or join other tubing.Tubing 40 may serve to host, house, and otherwise facilitate connectionof other components of the system 10 as is shown and described herein.

Manual Pressure Relief Valve In the arrangement shown, as one example,tube 40 includes a manual pressure relief valve 108. Manual pressurerelief valve 108 is formed of any suitable size, shape and design and isconfigured to facilitate manual venting of air pressure from tube 40. Inthe arrangement shown, as one example, manual pressure relief valve 108includes a valve body 110 and an operating mechanism 112. Valve body 110is formed of any suitable size, shape and design and is configured toselectively open to allow a desired amount of air out of tube 40 whendesired. In one arrangement, valve body 110 may be what is known as aglobe valve, or a butterfly valve, however any other form of a valve ishereby contemplated for use. Operating mechanism 112 is formed of anysuitable size, shape and design and is configured to facilitate manualcontrol of valve body 110. In the arrangement shown, as one example,operating mechanism 112 is formed of a handle that facilitates manualrotation of valve body 110, however any other configuration orarrangement is hereby contemplated for use that facilitates manualcontrol of valve body 110.

Dynamic Pressure Relief Valve: In the arrangement shown, as one example,tube 40 includes a dynamic pressure relief valve 114. Dynamic pressurerelief valve 114 is formed of any suitable size, shape and design and isconfigured to facilitate automatic and/or electronically controlledventing of air pressure from tube 40. In the arrangement shown, as oneexample, dynamic pressure relief valve 114 includes a valve body 116 andan actuator 118. Valve body 116 is formed of any suitable size, shapeand design and is configured to selectively open to allow a desiredamount of air out of tube 40 when desired and controlled to do so. Inone arrangement, valve body 116 is what is known as a butterfly valve,however any other form of a valve is hereby contemplated for use.

Actuator: Actuator 118 is formed of any suitable size, shape and designand is configured to facilitate automatic and/or electronic control ofvalve body 116. Actuator 118 is any device which receives power and acontrol signal and facilitates desired movement of valve body 116.Hydraulic and pneumatic actuators are also hereby contemplated for use.In one arrangement, as one example, an electronic Belimo actuatormanufactured by BELIMO Automation AG, Brunnenbachstrasse 1, 8340 Hinwil,Switzerland is used that includes a DC electric motor, overloadprotection, a direction control switch, an easy manual override button,easy mechanical stops to adjust angle of rotation, among other featuresand components. In one arrangement, actuator 118 includes a positionsensor 120 that provides a highly accurate position of dynamic pressurerelief valve 114 that facilitates highly accurate control of dynamicpressure relief valve 114.

In the arrangement shown, as one example, dynamic pressure relief valve114 and/or actuator 118 is electronically connected to and controlled bycentral controller 24, as is further described herein.

Pressure Sensor: In the arrangement shown, as one example, tube 40includes at least one pressure sensor 122. Pressure sensor 122 is formedof any suitable size, shape and design and is configured to sense thepressure within tube 40. That is, pressure sensor 122 is any devicewhich measures the pressure of gasses or fluids within tube 40. In onearrangement, pressure sensor 122 acts as a transducer in that itgenerates a signal as a function of the pressure imposed upon theoperable portions of the sensor. In the arrangement shown, as oneexample, pressure sensor 122 is positioned in tube 40 between blowermotor 106, manual pressure relief valve 108 and dynamic pressure reliefvalve 114 on one side, and rotary airlock 124 on the other side, howeverany other placement and/or position in tube 40 is hereby contemplated.In one arrangement, pressure sensor 122 may be positioned at any pointalong tube between blower motor 106 and rotary airlock 124.

In the arrangement shown, as one example, only a single pressure sensoris shown in use. This use of a single pressure sensor 122 may beacceptable in many applications as the pressure throughout the length oftube 40 may be relatively consistent. However, it is hereby contemplatedthat any number of pressure sensors 122 may be used at any positionalong the length of tube 40 such as two, three, four, five, six, seven,eight, nine or ten or more as may be needed or useful in a particularapplication. These additional pressure sensors 122 may be positioned atany position along the length of tube 40 and may be placed betweenrotary airlock 124 and dry grain bin 22. In the arrangement shown, asone example, pressure sensor(s) 122 is electronically connected to andprovides information to central controller 24, as is further describedherein.

Rotary Airlock: In the arrangement shown, as one example, system 10 isused in association with a rotary airlock 124. Rotary airlock 124 isformed of any suitable size, shape and design and is configured to metergrain 14 into tube 40 from grain dryer 18 in a controlled manner whileminimizing air pressure loss. Rotary airlock 124, also known as a rotaryairlock feeder, is any device that facilitates transferring materialbetween two vessels with differing pressures while minimizing air loss.In the arrangement shown, as one example, rotary airlock 124 includes ahousing 126 and a motor 128 among other features and components.

Housing 126 is formed of any suitable size, shape and design and isconfigured to meter grain 14 from its input 130 to its output 132 in acontrolled manner while minimizing air pressure loss. In the arrangementshown, as one example, housing 126 includes an exterior shell or housingthat contains metering vanes therein that causes the movement of grain14 from input 130 to output 132. In the arrangement shown, as oneexample, housing 126 is connected at its input 130 to the outlet 96 ofgrain dryer 18 such that grain 14 dispensed out of grain dryer 18 istransported to housing 126 where it is metered into tube 40 whileminimizing air pressure loss. In the arrangement shown, as one example,housing 126 is connected at its output 132 to tube 40 such that grain 14metered through housing 126 is transferred to tube 40, which thentransfers the grain 14 along the length of tube 40 under the airpressure and air flow within tube 40.

Motor 128 is formed of any suitable size, shape and design and isconfigured to facilitate operation of housing 126. In the arrangementshown, as one example, motor 128 is an electric motor that is connectedto a shaft of housing 126. In this arrangement, when motor 128 rotatesso rotates the internal components of housing 126. In one arrangement,the faster motor 128 rotates, the faster the internal components ofhousing 126 rotate thereby dispensing grain at a higher rate. Or, saidanother way, the higher the output or faster the output of motor 128 thehigher the output or faster the output of housing 126. Any other deviceother than an electric motor is hereby contemplated for use as motor 128such as a gas powered motor, a steam engine, a belt drive, a chaindrive, a gear drive, or any other source of power or rotational force.Also, while the motor 128 and housing 126 are shown as separate butoperably connected components, in another arrangement motor 128 andhousing 126 may be formed of a single integrated unit. Motor 128 andhousing 126 operate in concert with one another to facilitate thetransfer of grain 14 to tube 40 and as such, reference to one of motor128 and housing 126 may refer to both motor 128 and housing 126 and/orthe collective effect of motor 128 and housing 126 which is to dispensegrain 14 into tube 40. Also, while a single motor 128 and housing 126 isshown, it is hereby contemplated that two or more motors 128 and/orhousings 126 may be used.

In the arrangement shown, as one example, rotary airlock 124 and/ormotor 128 is electronically connected to and controlled by centralcontroller 24, as is further described herein.

Once grain 14 is dispensed into tube 40 from rotary airlock 124, thisgrain 14 is carried along the length of tube 40 in the air flow fromblower 103 until it is deposited through the opening 54 in roof 46 forstorage in dry grain bin 22.

Central Controller:

In the arrangement shown, as one example, system 10 is used inassociation with a central controller 24. Central controller 24 isformed of any suitable size, shape and design and is configured toreceive information from electronic components of system 10, processthis information according to instructions stored in memory and outputcommands thereby controlling operation of these electronic components.

In the arrangement shown, as one example, a single central controller 24is electronically connected to electronic components of system 10 and isconfigured to receive information from these electronic components aswell as output commands thereby controlling operation of theseelectronic components. While the term “central controller” is usedherein, this term is not intended to limit central controller 24 to onlya single centrally located electronic component or components housed ata single location. That is, central controller 24 may be formed of asingle electronic component or grouping of electronic components locatedat a single location or co-located position. Central controller 24 mayalso be a plurality of electronic components that are located indisparate locations but are electrically connected to one another andoperate in concert with one another through the sharing of informationto facilitate a desired outcome. In this way, the term “centralcontroller” is not intended to be limited by physical location. The term“central controller” is only intended to imply a centralized andcoordinated manner and method of control. Central controller 24 may beformed of a single electronic device, or any number of connectedelectronic devices.

At a high level, in one arrangement, central controller 24 controlsoperation of air system 20 as well as grain dryer 18 or any other deviceor system that serves as a source of grain 14 into air system 20 such asan auger, a grain leg, or the like. In this way, central controller 24may control the input of grain 14 into air system (from grain dryer 18or another source of grain 14) as well as control operation of airsystem 20 which conveys the grain 14). This allows central controller 24to optimize performance of air system 20 as well as react to changes inoperation as well as detect and anticipate plugs in air system 20 andbegin an unplugging routine in response to a plug.

In the arrangement shown, as one example, central controller 24 may beelectrically connected to and receive information from and controloperation of motor 64 of auger 58 of input device 16 and any relatedsensors; loading system 68, metering system 80, and discharge system 82of grain dryer 18 and any related sensors; and blower motor 106,actuator 118 and position sensor 120 of dynamic pressure relief valve114, pressure sensor 122 and motor 128 of rotary airlock 124 of airsystem 20 and any related sensors. By being electronically connected tothese electronic components central controller 24 may control, adjust(speed up or slow down), stop and start operation of these electroniccomponents in concert with one another.

In one arrangement, central controller 24 includes a processor 134 thatis electronically connected to memory 136 having instructions 138 storedtherein. Processor 134 is any computing device that receives andprocesses information and outputs commands according to instructions 138stored in memory 136. Memory 136 is any form of a device thatfacilitates information storage as well as retrieval such as flashmemory, ram memory, a hard drive, or any other form of memory. Memory136 and processor 134 may be formed of a single combined component, ormemory 136 and processor 134 may be formed of multiple co-located orseparated components that operate in concert with one another.Instructions 138 are any form of instructions that provide guidance toprocessor 134 as to how to interpret information and react toinformation and may be software, algorithms, code, parameters or thelike.

Variable Frequency Drive: In one arrangement, central controller 24includes and/or is electrically connected to a variable frequency drive140 (or VFD 140) which is electronically connected to and controlsoperation of blower motor 106. Variable frequency drive 140 is formed ofany suitable size, shape and design and is configured to adjustablycontrol operation of blower motor 106. Variable frequency drive 140,also known or referred to as an adjustable-frequency drive,variable-voltage/variable-frequency (VVVF) drive, variable speed drive,AC drive, micro drive or inverter drive is any type of anadjustable-speed drive used in electro-mechanical drive systems tocontrol AC motor speed and torque by varying motor input frequency andvoltage.

The use of variable frequency drive 140 allows the speed of blower motor106 to be adjusted and/or optimized. This allows the air pressure withintube 40 to be adjusted to desired levels by adjusting the rotationalspeed of blower motor 106. Variable frequency drive 140 adds cost andcomplexity to the system 10. However, the use of variable frequencydrive 140 allows central controller 24 to operate blower motor 106 in amore-efficient manner by matching the output of blower motor 106 withthe desired air pressure within tube 40 for optimum performance.

Without variable frequency drive 140, blower motor 106 is operated atfull capacity, regardless of the desired air pressure within tube 40.Then, to achieve the desired air pressure within tube 40, manualpressure relief valve 108 or dynamic pressure relief valve 114 is openedto the desired level to bleed off excessive air pressure within tube 40.This process is energy inefficient and wasteful, but it is simpler andmore cost-effective up-front as variable frequency drive 140 and thesupporting electronics and programming is complex and expensive.However, over time, due to the energy savings provided by use ofvariable frequency drive 140, implementing variable frequency drive 140provides cost savings.

Programmable Logic Controller: In one arrangement, central controller 24includes and/or is electronically connected to a programmable logiccontroller 142 (or PLC 142), which is electronically connected topressure sensor 122. Programmable logic controller 142 is formed of anysuitable size, shape and design and is fed and/or configured to read andtrack the pressure within tube 40 from pressure sensor 122 and inresponse thereto control operation of the variable frequency drive140/blower motor 106 and/or dynamic pressure relief valve 114/actuator118. Alternatively, this functionality is provided by central controller24 and/or another electronic component of the system 10.

Other Electronic Components: System 10 and/or central controller 24includes any other electronic component that is needed to controloperation of the system 10.

In one arrangement, system 10 and/or central controller 24 includesand/or is electrically connected one or more current sensors 144.Current sensor 144 is any device which senses the amount of current orenergy drawn or used by a motor. Current sensor 144 may be used inassociation with motor 64 of auger 58 of input device 16, any of themotors operating in association with grain dryer 18, blower motor 106,motor 128 of rotary airlock 124, or any other motor of the system 10.

In one arrangement, current sensor 144 is a standalone, separate andadded electronic component. In another arrangement, current sensor 144is incorporated within and/or within the functionality of anothercomponent of the system 10 such as within the motor, within variablefrequency drive 140, and/or within any other component of the system 10.In one arrangement, as variable frequency drive 140 senses current drawof the attached motor, variable frequency drive serves as the currentsensor 144 (and can also serve as the motor speed sensor 146, amongothers).

In one arrangement, system 10 and/or central controller 24 includesand/or is electrically connected to one or more motor speed sensors 146.Motor speed sensor 146 is any device which senses the rotational speedor other speed of a motor. Motor speed sensor 146 may be used inassociation with motor 64 of auger 58 of input device 16, any of themotors operating in association with grain dryer 18, blower motor 106,motor 128 of rotary airlock 124, or any other motor of the system 10.

In one arrangement, motor speed sensor 146 is a standalone, separate andadded electronic component. In another arrangement, motor speed sensor146 is incorporated within and/or within the functionality of anothercomponent of the system 10 such as within the motor, within variablefrequency drive 140, and/or within any other component of the system 10.

In one arrangement, system 10 and/or central controller 24 includesand/or is electrically connected to one or more grain speed sensors 148.Grain speed sensor 148 is any device which senses the speed of grain 14passing through the tube 40. However, approximate grain speed can bededuced from air pressure within tube 40.

In one arrangement, system 10 and/or central controller 24 includesand/or is electrically connected to one or more proximity sensors 150.Proximity sensor 150 is any device which senses the presence of or lackof presence of gain 14 at various positions along the path of grain 14in the system 10.

In one arrangement, system 10 and/or central controller 24 includesand/or is electrically connected to one or more position sensors 120.Position sensor 120 is any device which senses the position of acomponent of the system 10, such as the position of the dynamic pressurerelief valve 114 or the like.

Any other sensor that yields information that can be used to control thesystem 10 is hereby contemplated for use. With the information fromposition sensor(s) 120, pressure sensor(s) 122, current sensor(s) 144,motor speed sensor(s) 146, grain speed sensor(s) and proximity sensor(s)150

Human Machine Interface:

In the arrangement shown, as one example, system 10 is used inassociation with a human machine interface 152 (or HMI 152). Humanmachine interface 152 is formed of any suitable size, shape and designand is configured to facilitate human control of system 10 through theentry of information and commands and user controlled settings intosystem 10. In the arrangement shown, as one example, human machineinterface 152 is electronically connected to and facilitates control ofcentral controller 24, and therefore control of the system 10. In thearrangement shown, as one example, human machine interface 152 includesa touch screen that both displays information on a display 154 as wellas receives information through touching the screen by a user. Any otherform of a human machine interface is hereby contemplated for use such asa graphical user interface with a mouse arrangement, a keyboardarrangement, voice control and/or the like or any combination thereof.

In one arrangement, central controller 24 and/or human machine interface152 is electronically connected to the internet 26 through the cloud 28and/or a wireless network 30, such as a cell tower or the like. Thisconnection facilitates control of the system 10 remotely through auser's electronic device 32 such as a desktop or laptop computer 34, acell phone 36, a tablet 38 or any other computing device. This isaccomplished through the display of display 154 on the user's electronicdevice 32 and the transfer of commands and information between thesystem 10 on one side and the user on the other side through use of theuser's electronic device 32.

In Operation—System with Manual Pressure Relief Valve and No DynamicPressure Relief Valve or Variable Frequency Drive:

In this example of operation of grain handling system 10 this example ofgrain handling system 10 includes an input device 16, a grain dryer 18,and an air system 20 and does not include a dynamic pressure reliefvalve 114 or a variable frequency drive 140. In this example, without avariable frequency drive 140 blower motor 106 is started with a linestart or a soft start or the like and blower motor 106 is continuouslyoperated at or near full capacity or at another static capacity. Thatis, without variable frequency drive 140, in one arrangement, blowermotor 106 is essentially operated in a binary manner. That is, blowermotor 106 is either on, at full capacity or another static capacity, oroff. This is because system 10 and/or central controller 24 lacks theability to dynamically adjust the speed of blower motor 106 in responseto changes in the operation of the system 10.

When blower motor 106 is operated at full capacity it is likely thatblower motor 106 is supplying too much air to tube 40 and as a resultthe grain 14 may be damaged as it passes through tube 40. To correctthis problem and to reduce the speed of the grain 14 as it passesthrough tube 40 manual pressure relief valve 108 is manually operated byoperating mechanism 112 which opens and closes valve body 110 until thedesired amount of air is bled from tube 40. Bleeding air from tube 40has the result of moving grain 14 through tube 40 at a desired reducedspeed that maximizes capacity while minimizing damage to grain 14. Assuch, speed of the grain 14 traveling through tube and capacity must becarefully balanced to maximize capacity while minimizing damage to grain14. In one arrangement it is desirable to aim for anywhere between threeor four PSI within tube 40 on the low end of the range and eight PSI onthe upper end of the range, with approximately six PSI as the target.

While this arrangement is effective when set, one problem with thisarrangement is that air system 20 has a tendency to plug when operatedat or near its limits. Changes in humidity, outside air temperature,moisture content of grain 14, temperature of grain 14, debris or finescontent in grain 14, the rate at which grain 14 is added to tube 40, theconsistency or variability at which grain 14 is added to tube 40, weightof grain 14, size of grain 14, or countless other variables have atendency to affect operation of air system 20. As these factors areconstantly changing it is hard to set air system 20 to its maximumcapacity without risking damaging grain 14 and/or plugging tube 40. Assuch, this manual system 10 requires constant attention and constantmanual adjustment to ensure optimum efficiency with maximum capacitywhile minimizing damage to grain 14.

In many cases, to avoid plugging of the air tube 40, and to compensatefor this arrangement's inability to adjust to variations in operation,in practice users tend to set the air system 20 in a very conservativemanner. That is, that air system 20 is set such that the amount of grain14 introduced into the air tube 40 is well below the full capacity ofthe air system 20. This conservative setting is intended to avoidplugging at practically all costs because in this arrangement when aplug occurs a fault setting is triggered (which may either be an airpressure fault in air tube 40, a current draw fault in blower motor 106or another fault) the entire system 10 is shut down until manualattention is provided to clear the plug. This has the result ofsubstantially reducing the throughput of grain 14 through the air tube40 as well as overly-damaging grain 40 as it passes through air tube 40.Again, this is because these drawbacks are substantially better thanfacing continual shutdowns due to plugs.

In addition to the above, it is energy inefficient to run blower motor106 at maximum capacity or a higher capacity than is needed and thenbleeding off a portion of the air pressure generated.

Another problem with this manual system is that it does not have afeedback loop that can adjust to changes in the variables that affectthe air system 20.

More specifically, in this arrangement, central controller 24 mayreceive signals regarding the operation of the system 10 from some orall of the following sensors:

-   -   Pressure sensors 122 that provide the air pressure within tube        40;    -   Current sensors 144 that provide the current or power draw of        the connected motor, such as motor 64 of auger 58 of input        device 16, motors associated with grain dryer 18 such as loading        system 68, metering system 80 (interior metering roll 84,        exterior metering roll 86), discharge system 82, blower motor        106 of blower 103, the motor of dynamic pressure relief valve        116, motor 128 of rotatory airlock 124, and/or any other motor        of the system;    -   Motor speed sensors 146 that provide the speed of the connected        motor, such as motor 64 of auger 58 of input device 16, motors        associated with grain dryer 18 such as loading system 68,        metering system 80 (interior metering roll 84, exterior metering        roll 86), discharge system 82, blower motor 106 of blower 103,        motor 128 of rotatory airlock 124, and/or any other motor of the        system;    -   Grain speed sensors 148 that provide the speed of grain 14        moving through tube 40 or through other components of the system        10 such as into, through or out of wet grain bin 12, input        device 16, grain dryer 18, air system 20, dry grain bin 22        and/or any other component of the system 10;    -   Proximity sensors 150 that provides information regarding the        presence of grain 14 at any positon of system 10 including tube        40, wet grain bin 12, input device 16, grain dryer 18, air        system 20, dry grain bin 22 and/or any other component of the        system 10;    -   Any other sensor connected with system 10.

Central controller 24 may also receive information regarding operationof any other component of the system 10. In response to receiving thisinformation, central controller 24 processes this information usingprocessor 134 and/or programmable logic controller 142 accordinginstructions 138 stored in memory 136 and outputs commands that controlsthe electronic components of the system 10.

Central controller 24 may control operation of the connected electroniccomponents. However, central controller 24 cannot adjust the speed ofblower motor 106 as this manual system 10 lacks variable frequency drive140 that is controlled by central controller 24. In addition, centralcontroller 24 cannot adjust the position of a bleed valve as this manualsystem 10 lacks a dynamic pressure relief valve 114 that is controlledby central controller 24. As such, while central controller 24 maymonitor operation of various components of the system 10, centralcontroller 24 has limited options as to how to respond.

In one arrangement, as one example, with reference to FIG. 5 ademonstrative chart showing air pressure in normal operation as well aswhen a plug occurs is presented. On this demonstrative chart, PSI isshown as the vertical axis, and time is the horizontal axis. On thisdemonstrative chart, the set point is shown as the dashed line “S”, theupper limit to the normal range of operation is shown as the dashed line“U”, and the lower limit to the normal range of operation is shown asthe dashed line “L.” On this demonstrative chart, the fault line isshown as the dashed line “F” which indicates when a fault has occurred,and the early detection line is shown as the dashed line “E” whichindicates a point where the central controller 24 may determine that theearly signs of a plug have occurred. In one arrangement, these pointsmay be set by the user or they may be set by the central controller 24during operation.

As one example of operation, with reference to FIG. 5 , centralcontroller 24 receives pressure information regarding the air pressurewithin tube 40 from pressure sensor 120 and central controller 24 tracksthis information. As is shown on the demonstrative graph of FIG. 5 , forthe majority of the graph the sensed pressure oscillates around six PSIwithin the desired range between four PSI and eight PSI. This indicatesexpected normal operation where grain 14 is flowing through tube 40 at ahigh capacity while not overly damaging the grain 14.

This normal operation continues until the PSI crosses the “U” line whichindicates the upper limit of normal operation which in this example iseight PSI. This is shown as point “A” on the chart. This indicates aspike in pressure which indicates a plug may be occurring or justoccurred in tube 40 which is detected by central controller 24 usingprocessor 134 and instructions 138 stored in memory 136. This increasein pressure continues until the air pressure crosses the early detectionline “E” at point “B” which indicates an early detection of a plug hasoccurred as this point is well outside of the boundaries of normaloperation while being well short of a fault, shown as fault line “F”. Atthe point where the PSI crosses the vertical dashed line, atapproximately twelve PSI at point “C”, central controller 24 usingprocessor 134 and instructions 138 stored in memory 136 confirms that aplug has occurred in tube 40 and a fault is tripped. Again, theseparameters “S,” “L,” “U,” “E,” and/or “F” may be user defined, preset ordetermined in a dynamic fashion by central controller 24 using processor134 and instructions 138 stored in memory 136. Early detection “E” andfault “F” can be determined by central controller 24 using processor 134and instructions 138 stored in memory 136 based on the speed and/ormagnitude of a move in a sensed parameter.

As an alternative and/or redundant manner of detecting when a plugoccurs, in one arrangement, with reference to FIG. 6 , a similardemonstrative graph is presented that shows current draw as opposed toPSI shown in FIG. 5 . In this arrangement, central controller 24receives current draw information regarding the current draw of blowermotor 106 from current sensor 144. As is shown on the demonstrativegraph of FIG. 6 , for the majority of the graph the sensed current drawoscillates around set point “S” within the desired range between upperlimit “U” and lower limit “L” before spiking at the end of the graph andcrossing early detection line “E” and eventually fault line “F” in asimilar manner to that shown on FIG. 5 in PSI. At the point where thecurrent draw crosses the vertical dashed line “F” indicating a fault hasoccurred, central controller 24 using processor 134 and instructions 138stored in memory 136 confirms that a plug has occurred in tube 40.

As an alternative and/or redundant manner of detecting when a plugoccurs, information from any other sensor or any other source ofinformation may be used to determine that a plug has occurred such asmotor speed sensor 146, grain speed sensor 148, proximity sensor 150 orany other sensor.

In response to detecting a plug has occurred, central controller 24shuts down the entry of grain 14 into tube 40 so as to prevent the plugfrom getting worse. This may occur by stopping operation of any and/orall components of system 10 or more specifically by stopping rotation ofmotor 128 of rotary airlock 124 and/or stopping operation of dischargesystem 82, metering system 80 and/or loading system 68 of grain dryer18, and/or stopping operation of motor 64 of auger 58 of input device 16and/or stopping operation of any other component or components of thesystem 10. This is shown in a demonstrative graph of FIG. 7 wherein theunload motor speed of the motors identified herein (such as motor 128 ofrotary airlock 124 and/or the motors associated with discharge system82, metering system 80 and/or loading system 68 of grain dryer 18,and/or motor 64 of auger 58 of input device 16 and/or any other motor ofthe system) operate until the vertical line on the graph at which pointcentral controller 24 stops operation of the motor(s).

Once the flow of grain 14 has been stopped, central controller 24 hasensured that the plug is not made worse. Thereafter, in one arrangementcentral controller 24 using processor 134 and instructions 138 stored inmemory 136 continues operation of blower motor 106 in an attempt toclear the plug. In this arrangement, blower motor 106 may be operatedfor a predetermined amount of time, until a limit has been hit orexceeded (such as a pressure limit, current draw limit, motor speedlimit, motor temperature limit, time limit or any other limit) and/oruntil a calculated limit is reached or exceeded based on an algorithm orother programming. If the plug is not cleared, central controller 24stops blower motor 106 so as to protect blower motor 106 from damageand/or self-destruction.

Once the blower motor 106 has been stopped, with the plug remaining intube 40, manual labor is required to clear the plug.

It is worthwhile to note, that when a plug is detected in thisarrangement, central controller 24 has limited options as to how torespond as the central controller 24 is not connected to a variablefrequency drive 140 that can ramp up and ramp down operation of blowermotor 106, and is also not connected to a dynamic pressure relief valve114 having a controllable actuator 118 that can be used to selectivelybleed air from tube 40. As such, to save blower motor 106, all centralcontroller 24 can do is shut down the flow of grain 14 into tube 40 andsimultaneously or later shut down operation of blower motor 106 after alimited amount of time of additional operation of blower motor 106. Itis unlikely that this limited amount of time of continued operation ofblower motor 106 after a plug has occurred will clear the plug.

Early Detection: One of the benefits of the system 10 is that itprovides early detection of a plug and in view of early detection of apotential plug the system 10 can make adjustments to avoid the plug,minimize the plug and/or clear the plug. In one arrangement, when theair pressure crosses the early detection line “E” central controller 24using processor 134 and instructions 138 stored in memory 136 determinesthat an early detection of a plug has occurred or the early signs of aplug have appeared in the operational characteristics of the system 10.This early detection of a plug occurs well above the upper limit line“U” and well before the fault line or parameter “F,” however that maynot always be the case depending on the starting position, the speedand/or magnitude of a move in a sensed parameter (meaning that an earlydetection of a plug can occur within the upper and lower limits ofnormal operation so long as the move meets other speed or magnitudecharacteristics thereby allowing for its early detection.

In response to this early detection, in this arrangement, centralcontroller 24 using processor 134 and instructions 138 stored in memory136 stops or alternatively slows down the entry of grain into air tube40 by slowing or stopping rotary airlock 124, and/or by slowing orstopping the flow of grain 14 into rotary airlock 124 by closing a gate156 in or along input tube 158 and/or surge bin 160 which facilitatesthe flow of grain 14 into rotary airlock 124, and/or by slowing orstopping the flow of gain 14 into rotary airlock 124 by slowing orstopping discharge system 82 of grain dryer 18 and/or metering system 80of grain dryer 18 and/or slowing or stopping any other component of thesystem that facilities the flow of grain 14 to rotary airlock 124 and/orair system 20. This is so as to ensure that more gain 14 is not added tothis potential plug, thereby making the plug worse. Sensing an earlydetection of a plug and stopping, or at least slowing down, the flow ofgrain 14 into air tube 40 in response to an early detection of a plugstops or limits the amount of grain 14 that enters air tube 40 in thetime between the early detection line “E” and the fault line “F.”

If the potential plug clears, and the air pressure drops in responsethereto, central controller 24 using processor 134 and instructions 138stored in memory 136 detects this drop in air pressure and againautomatically reinitiates the flow of grain into air tube 40. In doingso, central controller 24 using processor 134 and instructions 138stored in memory 136 in an attempt to avoid another plug centralcontroller 24 using processor 134 and instructions 138 stored in memory136 starts metering grain 14 into air tube 40 at a slow or slowerinitial rate. Thereafter, central controller 24 using processor 134 andinstructions 138 stored in memory 136 monitors the air pressure in airtube 40 for a period of time ensuring that another plug does not occurduring the initial reentry of grain. Central controller 24 usingprocessor 134 and instructions 138 stored in memory 136 continues toiteratively increase the amount of grain added to air tube 40 followedby periods of monitoring the air pressure in the air tube 40 until thedesired air pressure range is achieved.

In this way, system 10 may be used to early detect when a plug hasoccurred and quickly take preventative and corrective measures. In thisway, system 10 may be used to continually push up the through-put of theair system 20 by continually trying to increase the amount of grain 14added to air tube 40 and when an early detection of a plug occurs, theflow of grain is stopped or reduced thereby allowing the potential plugto clear before the central controller 24 using processor 134 andinstructions 138 stored in memory 136 again tries to resume normal,maximized, operation (while avoiding plugs).

In this way, the system 10 presented herein (even without the use ofdynamic pressure relief valve 114 and/or variable frequency drive 140)may be used to maximize through put of air system 20 while providingsome of the self-clearing functions by quickly detecting that a plugcould be occurring and in response adjusting the flow of grain 14 intoair tube 40. During operation of this arrangement, central controller 24using processor 134 and instructions 138 stored in memory 136 may adjustthe flow of grain 14 into air tube 40 up or down as dyna mics changewithin the system 10 thereby maximizing throughput of air system 20while reducing the potential for a plug.

As the through-put of the air system 20 is increased, central controller24 using processor 134 and instructions 138 stored in memory 136 mayin-turn increase the throughput of grain dryer 18 or any other inputdevice 16. This may include increasing the plenum temperature (alsoknown as the drying temperature), the fan speed, the speed of themetering system 80 (metering rolls 84, 86), the speed of the dischargesystem 82, the speed of loading system 68, and/or the speed oroperational parameter of any other portion of the grain dryer 18. Assuch, in this way, by providing a hand-shake and exchange of dynamicinformation between the grain dryer 18 and the air system 20, which hasnever been done before, both the grain dryer 18 and the air system 20may be run at their maximum capacity and maximum efficiency in realtime, automatically and without user intervention. Never before hasinformation been shared between a grain dryer 18 and an air system 20through a central controller 24 that allows improved control of an airsystem 20 based on the dynamic and real time operational parameters of agrain dryer 18, and vice versa, that allows improved control of a graindryer 18 based on the dynamic and real time operational parameters of anair system 20.

The system 10 presented herein allows for maximized and optimizedoperation of an air system 20 as well as an input system 16, such as agrain dryer 18 in concert with one another. It is undesirable to haveeither an air system 20 or an input system 16, such as a grain dryer 18,run substantially faster or slower than the other. Instead, it isdesirable to maximize the output of the slower of an air system 20 or aninput system 16, such as a grain dryer 18, and balance the other of anair system 20 or an input system 16, such as a grain dryer 18, tooptimize its operation to the desired input or output. The system 10presented herein facilitates this optimized operation through theinterconnection and data sharing between air system 20 and grain dryer18 and mutual control of the air system 20 and grain dryer 18 throughcentral controller 24.

Fault Limit Reached: In the event that a fault limit is reached and/orexceed, such as at point “C” on FIG. 5 when the PSI line crosses thefault line “F,” in one arrangement, (without dynamic pressure reliefvalve 114 and/or variable frequency drive 140) central controller 24shuts down the flow of grain 14 into air tube 40 as well as shuts downoperation of blower motor 106. By shutting down operation of blowermotor 106 this lets the air pressure within air tube 40 dissipate suchthat the air pressure within the tube balances with atmosphericpressure. By allowing all air pressure to dissipate this may have theeffect of clearing, breaking up or loosening the plug. Thereafter, aftera predetermined amount of time, central controller 24 again reinitiatesthe operation of blower motor 106. In doing so, blower motor 106 againpressurized air tube 40.

If, after shutting down blower motor 106, waiting a predetermined amountof time, and then reinitiating operation of blower motor 106 centralcontroller 24 detects the plug has cleared, central controller 24resumes normal operation as is described herein, such as by slowlyincreasing the flow of grain 14 into air tube 40 until operation isagain maximized. If, after reinitiating operation of blower motor 106the plug remains and the pressure or current draw or other parameterspikes to the fault “F” position, the central controller 24 again shutsdown operation of the blower motor 106, waits a predetermined amount oftime for the pressure to clear before starting blower motor 106 again.

This turning on and turning off of blower motor 106 may be performediteratively any number of cycles such as 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10or more times until either the plug clears and normal operation resumeswithout manual intervention being required, or alternatively centralcontroller 24 determines that the plug cannot be automatically clearedand manual intervention is required. This allows for potentialauto-clearing of a plug by central controller 24 even without system 10having a dynamic pressure relief valve 114 and/or a variable frequencydrive 140. As such, this iterative turning on and turning off of blowermotor 106 may be considered an unplugging routine.

In Operation—System with Dynamic Pressure Relief Valve and No VariableFrequency Drive:

In this example of operating grain handling system 10, grain handlingsystem 10 includes an input device 16, a grain dryer 18, an air system20 and a dynamic pressure relief valve 114 and does not include avariable frequency drive 140. In this example, with the addition of adynamic pressure relief valve 114, all of the operational teachingspresented above with respect to a system 10 without either a dynamicpressure relief valve 114 or a variable frequency drive 140 apply withthe added ability to adjust the pressure relief valve 114. That is, allprior teaching herein is incorporated into and applicable to thisexample (unless stated otherwise) as well as the further teachingpresented below.

In this example, blower motor 106 is continuously operated at or nearfull capacity or at another static capacity. That is, without variablefrequency drive 140, in one arrangement, blower motor 106 is essentiallyoperated in a binary manner. That is, blower motor 106 is either on, ator near full capacity or another static capacity, or off, as system 10lacks the ability to adjust the speed of blower motor 106.

In this arrangement, central controller 24 receives signals regardingthe operation of the system 10 from some or all of sensors identifiedabove in the system 10 with the manual pressure relief valve 108. Inaddition this system 10 includes at least one position sensor 120 thatprovides the position information of dynamic pressure relief valve 114having an actuator 118.

In this arrangement, during operation of the system 10, centralcontroller 24 tracks air pressure in tube 40 through pressure sensor 122as well as current draw of blower motor 106 through current sensor 144,as well as any other information from any other sensor or component ofthe system 10.

In this arrangement, in response to the information received by centralcontroller 24, using processor 134 and instructions 138 stored in memory136, central controller 24 may precisely adjust the position of dynamicpressure relief valve 114 by controlling operation of valve body 116using electronic control of actuator 118. In doing so, the preciseposition of the valve body 116 is reported back to central controller 24in a feedback loop using position sensor 120. In addition, the pressurewithin tube 140 is continuously fed back to central controller 24 bypressure sensor 122. In this way, and with this feedback loop ofcontinuous pressure and position information, central controller 24 mayadjust the amount of air that is bled-off of tube 40 so as to maintainoptimum pressure within tube 40. In this way, system 10 with theaddition of dynamic pressure relief valve 116, central controller 24 mayadjust for varying factors (such as changes in humidity, outside airtemperature, moisture content of grain 14, temperature of grain 14,debris or fines content in grain 14, the rate at which grain 14 is addedto tube 40, the consistency or variability at which grain 14 is added totube 40, weight of grain 14, size of grain 14, or any other variable)that affect performance of the system 10.

In this arrangement, when a plug is detected in tube 40, in addition toshutting down the flow of grain 14 into tube 40 in an attempt to preventthe plug from getting worse, as is described herein, central controller24 may also adjust the positon of dynamic pressure relief valve 116.

Early Detection: One of the benefits of the system 10 is that itprovides early detection of a plug and in view of early detection of apotential plug the system 10 can make adjustments to avoid the plug,minimize the plug and/or clear the plug. In response to this earlydetection, in this arrangement, central controller 24 using processor134 and instructions 138 stored in memory 136 stops or alternativelyslows down the entry of grain into air tube 40 by slowing or stoppingrotary airlock 124, and/or by slowing or stopping the flow of grain 14into rotary airlock 124 by closing a gate 156 in or along input tube 158and/or surge bin 160 which facilitates the flow of grain 14 into rotaryairlock 124, and/or by slowing or stopping the flow of grain 14 intorotary airlock 124 by slowing or stopping discharge system 82 of graindryer 18 and/or metering system 80 of grain dryer 18 and/or slowing orstopping any other component of the system that facilities the flow ofgrain 14 to rotary airlock 124 and/or air system 20. This is so as toensure that more gain 14 is not added to this potential plug, therebymaking the plug worse. In addition, with the additional control providedby the addition of dynamic pressure relief valve 114 to system 10,central controller 24 quickly reacts and closes dynamic pressure reliefvalve 114.

By closing dynamic pressure relief valve 114 upon the early detection ofa plug, central controller 24 ensures that all of the power provided byblower motor 106 is directed to clearing the potential plug in the airtube 40 or preventing the potential plug from forming into an actualplug. This has the tendency to reduce the potential for a plug to occurand fault limit “F” to be hit at point “C”.

If the potential plug clears, and the air pressure drops in responsethereto, central controller 24 using processor 134 and instructions 138stored in memory 136 detects this drop in air pressure and again seeksto control the system 10 to optimum equilibrium operation again. This isaccomplished again by automatically reinitiating the flow of grain intoair tube 40. In doing so, central controller 24 using processor 134 andinstructions 138 stored in memory 136 in an attempt to avoid anotherplug central controller 24 starts metering grain 14 into air tube 40 ata slow or slower initial rate. Simultaneously, central controller 24using processor 134 and instructions 138 stored in memory 136 controlsoperation of dynamic pressure relief valve 114. In doing so, centralcontroller 24 using processor 134 and instructions 138 stored in memory136 in an attempt to avoid another plug central controller 24 initiallymaintains dynamic pressure relief valve 114 in a position that is closedor more-closed than during optimum continuous operation, again, so as toavoid plugging again. In this way, central controller 24 simultaneouslycontrols the rate of flow of grain 14 into air system 20 while alsocontrolling the amount of air pressure that is bled off using dynamicpressure relief valve 114.

In one arrangement, central controller 24 using processor 134 andinstructions 138 stored in memory 136 monitors the air pressure in airtube 40 for a period of time ensuring that another plug does not occurduring the initial reentry of grain 14. Central controller 24 usingprocessor 134 and instructions 138 stored in memory 136 continues toiteratively increase the amount of grain 14 added to air tube 40followed by periods of monitoring the air pressure in the air tube 40until the desired air pressure range is achieved. Simultaneously,central controller 24 is used to open and/or close dynamic pressurerelief valve 114. In this way, central controller 24 continuously and inreal time balances the amount of grain 14 flowing into air tube 40 withthe amount of air bled through dynamic pressure relief valve 114 withthe air pressure within air tube 40. In one arrangement, centralcontroller 24 iteratively continues to increase grain flow into air tube40 while iteratively opening dynamic pressure relief valve 114 untiloptimum equilibrium operation is achieved.

In this way, central controller 24 controls operation of air system 20having a dynamic pressure relief valve 114 in an optimum and maximizedoperation while avoiding plugs.

Unplugging Routine: In one arrangement, when a plug is detected in tube40, central controller 24 may begin what is known as an unpluggingroutine.

In one arrangement, a plug is detected when the air pressure in air tube40 and/or current draw of blower motor 106 reaches point “C” on FIGS. 5and 6 respectively. If a plug occurs and an early detection routine wasperformed, as is described herein, this means the early detectionprocess was not successful in avoiding the plug.

When central controller 24 detects a plug has occurred, centralcontroller 24 immediately shuts down the additional flow of grain 14into tube 40, if it wasn't already shut down. Thereafter, in onearrangement, as an initial step, central controller 24 closes thedynamic pressure relief valve 114 either partially or all the way to afully closed position in an effort to power the plug through tube 40. Inthis initial step, the central controller 24 is essentially leaning onthe plug with its full force in an attempt to move the plug and/or breakit apart. This application of full force to the plug is performed eitheruntil the plug is cleared, until a predetermined amount of time passesand the central controller 24 determines the plug cannot be cleared byleaning on the plug, or until a fault occurs (it should be noted that insome cases it is undesirable to run the system 10 to the point where afault occurs as this may cause wear on parts of the system 10, andhitting a fault may automatic shutting down of various components of thesystem 10 which require later restarting, either automatically ormanually, before operation can continue).

Thereafter, central controller 24 attempts to self-clear the plug intube 40 by opening and closing dynamic pressure relief valve 114 byelectronically controlling actuator 118 which controls operation ofvalve body 116. In one arrangement, valve body 116 is moved in adramatic, drastic or substantial manner, such as between a fully openedand fully closed position (or any position between a fully opened andfully closed position) so as to cause the greatest variation in airpressure applied to the plug. In one arrangement, central controller 24pauses or maintains valve body 116 in a fully opened or fully closedmanner for a predetermined amount of time to cause as substantial animpact as possible without jeopardizing blower motor 106. In onearrangement, central controller moves actuator 118 as fast as possiblebetween the fully open and fully closed position (or any positionbetween a fully opened and fully closed position) so as to cause themost dramatic shift in air pressure within tube 40 in the shortestamount of time or desired amount of time.

By moving valve body 116 between the fully open and fully closedposition (or any position between a fully opened and fully closedposition) while operating blower motor 106 at full capacity (or anyother set amount) this causes a pulsing flow of air pressure to flowthrough tube 40. When these iterative pulses impact the plug in tube 40these pulses have a tendency to either break the plug apart and returnit to flowing material, or alternatively these pulses have a tendency tobump the plug along the length of tube 40 until the plug clears the endof tube 40 and is deposited into dry grain bin 22 (after which normaloperation of the system 10 may be automatically restored).

In one arrangement, central controller 24 is configured to continue thisiterative pulsing of the unplugging routine in an attempt to clear theplug for a predetermined amount of time and/or a predetermined number ofcycles (or pulses). If central controller 24 is capable of automaticallyclearing the plug in tube 40 the central controller 24 resumes normaloperation of the system 10 such as re-introducing the flow of grain 14into tube 40, restarting grain dryer 18 and all the associated systemsand motors therein, restarting input device 16 and the like.

As such, in this arrangement, central controller 24 automaticallydetected a plug in tube 40, automatically shut down components of thesystem 10 to stop the flow of grain 14 into tube 40 to prevent the plugfrom getting worse, automatically entered into an unplugging routine,automatically cleared the plug, automatically detected the plug wascleared, and then automatically restarted normal operation of the system10. This is all without user intervention. This is also withoutjeopardizing damage to components of the system 10. During theunplugging routine, blower motor 106 is protected by fault switchesand/or fault settings that shut down operation of the blower motor 106if the temperature of blower motor 106 reaches a fault setting, ifcurrent draw of blower motor 106 reaches a fault setting, if thepressure within the air tube 40 reached a fault setting, or if any otherparameter reaches a fault setting.

In the event that after a predetermined amount of time or number ofcycles or attempts or a calculated amount of attempts at pulsing orbumping the plug in tube 40, central controller 24 determines it is notcapable of clearing the plug in tube 40, central controller 24 shutsdown operation of blower motor 106 so as to preserve blower motor 106and to preserve energy. In concert with determining that the plug intube 40 cannot be automatically cleared, a fault message is transmittedby central controller 24 through the internet 26, the cloud 28 and/orwireless network 30 to a user's electronic device 32 such as theirdesktop or laptop computer 34, their cell phone 36, their tablet 38and/or any other device in the form of a text message, an app message, avoice message, an email, an alert, or any other message therebyinforming them that a plug has occurred and operation of the system 10has been shut down.

A demonstrative graph of this unplugging routine is shown in FIG. 9 . Inthis arrangement, the PSI within tube 40 is shown oscillating between aminimum value and a maximum value in an iterative manner until the plugis cleared. That is, in the arrangement shown, the PSI begins at aminimum level, at or around approximately two PSI corresponding todynamic pressure relief valve 114 being fully opened where most of theair pressure from blower motor 106 is vented away. Thereafter, the PSIquickly ramps up as the dynamic pressure relief valve 114 is quicklyclosed. This continues until the PSI reaches a maximum amount at oraround ten PSI corresponding to dynamic pressure relief valve 114 beingmostly or fully closed. Thereafter, the PSI quickly ramps down as thedynamic pressure relief valve 114 is quickly opened. This process isrepeated. This iterative process continues until the plug in tube 40 iscleared or broken up at or near the dashed vertical line which shows thePSI dropping to approximately one PSI.

This graph of FIG. 9 is only one of countless examples of an unpluggingroutine and is intended only to be demonstrative in nature. The shape ofthis graph may change dramatically by opening and closing the dynamicpressure relief valve 114 in different ways, keeping the dynamicpressure relief valve 114 opened or closed for shorter or longer amountsof time, or dynamically changing how the dynamic pressure relief valve114 is opened and/or closed, all of which are hereby contemplated foruse. As one example, the system 10 may “lean” on the plug for a longerperiod of time in hopes of clearing the plug without shorting orfaulting any of the components of the system 10 which results in thepeaks of the graph or curve extending laterally longer than what isshown in FIG. 9 . However, again, any other shape to the graph may beachieved and therefore is hereby contemplated for use.

It is worthwhile to note, that in this arrangement, system 10 does nothave a variable frequency drive 140 and therefore the central controller24 is unable to adjust the speed of blower motor 106 other than shuttingblower motor 106 off. As such, the unplugging routine is performedessentially exclusively through the operation of dynamic pressure reliefvalve 114.

In Operation—System with Variable Frequency Drive and No DynamicPressure Relief Valve:

In this example of operating grain handling system 10, grain handlingsystem includes an input device 16, a grain dryer 18, an air system 20and a variable frequency drive 140 and does not include a dynamicpressure relief valve 114. In this example, the level of operation ofblower motor 106 may be varied by variable frequency drive 140. In thisexample, with the addition of a variable frequency drive 140, all of theoperational teachings presented above with respect to a system 10 only adynamic pressure relief valve 114 as well as with respect to a system 10without either a dynamic pressure relief valve 114 or a variablefrequency drive 140 apply with the added ability to adjust the speed ofblower motor 106 using variable frequency drive 140. That is, all priorteaching herein is incorporated into and applicable to this example aswell as the further teaching presented below.

In this arrangement, the speed of blower motor 106 is adjusted toprovide the desired amount of air pressure within tube 40. As such,dynamic pressure relief valve 114 is not needed to bleed off excessiveair pressure as the blower motor 106 is operated at the desired level togenerate the desired air pressure and therefore there is no need tobleed off excess air pressure. While the inclusion of a variablefrequency drive 140 increases the initial price of the system 10 andincreases the complexity of the system 10, over time the inclusion ofvariable frequency drive 140 reduces cost by reducing power consumptionand increasing the efficiency of operation of the system 10. Inaddition, the elimination of the dynamic pressure relief valve 114reduces initial cost and complexity of the system 10.

In this arrangement, central controller 24 receives signals regardingthe operation of the system 10 from some or all of sensors identifiedabove in the system 10 with the manual pressure relief valve 108.

In this arrangement, during operation of the system 10, centralcontroller 24 tracks air pressure in tube 40 through pressure sensor 122as well as current draw of blower motor 106 through current sensor 144,as well as any other information from any other sensor or component ofthe system 10.

In this arrangement, in response to the information received by centralcontroller 24, using processor 134 and instructions 138 stored in memory136, central controller 24 in concert with variable frequency drive 140precisely adjust the speed of operation and/or output of blower motor106. In this way, blower motor 106, using variable frequency drive 140,is operated to provide the desired air pressure within tube 40, not moreand not less. In doing so, the level of operation of blower motor 106 isreported back to central controller 24 and/or variable frequency drive140 in a feedback loop using pressure sensor 122, current sensor 144,motor speed sensor 146, grain speed sensor 148 and/or any other sensor.In this way, and with this feedback loop of continuous pressureinformation and operation information, central controller 24 in concertwith variable frequency drive 140 may adjust the level of operation ofblower motor 106. In this way, system 10 with the addition of variablefrequency drive 140, central controller 24 may adjust for varyingfactors (such as changes in humidity, outside air temperature, moisturecontent of grain 14, temperature of grain 14, debris or fines content ingrain 14, the rate at which grain 14 is added to tube 40, theconsistency or variability at which grain 14 is added to tube 40, weightof grain 14, size of grain 14, or any other variable) that affectperformance of the system 10.

The result of using variable frequency drive 140 is that blower motor106 tends to operate at a substantially reduced speed, at asubstantially reduced load, while consuming substantially less energy,and while enduring substantially less wear and tear. With reference toFIG. 8 , a demonstrative graph is shown which shows the level ofoperation of blower motor 106 substantially below the maximum capacity.That is, until a plug is detected, which is shown at approximately thevertical dashed line, and thereafter blower motor 106 is ramped up tofull capacity.

Early Detection: As is described herein, when a plug is detected, orearly detection indicates that a plug may be forming, central controller24 stops the flow of grain 14 into tube 40 to prevent the plug fromgetting worse, and central controller 24 through the use of variablefrequency drive 140 ramps up operation of blower motor 106 to full ornear full output.

By ramping up operation of blower motor 106 upon the early detection ofa plug, central controller 24 ensures that full power of blower motor106 is applied to clearing the potential plug in the air tube 40 orpreventing the potential plug from forming into an actual plug. This hasthe tendency to reduce the potential for a plug to occur and fault limit“F” to be hit at point “C”.

If the potential plug clears, and the air pressure drops in responsethereto, central controller 24 using processor 134 and instructions 138stored in memory 136 detects this drop in air pressure and again seeksto control the system 10 to optimum equilibrium operation again. This isaccomplished again by automatically reinitiating the flow of grain intoair tube 40. In doing so, central controller 24 using processor 134 andinstructions 138 stored in memory 136 in an attempt to avoid anotherplug central controller 24 starts metering grain 14 into air tube 40 ata slow or slower initial rate. Simultaneously, central controller 24using processor 134 and instructions 138 stored in memory 136 controlsoperation of variable frequency drive 140 to control operation of blowermotor 106. In doing so, central controller 24 using processor 134 andinstructions 138 stored in memory 136 in an attempt to avoid anotherplug central controller 24 initially maintains operation of blower motor106 at an elevated output or slightly elevated output as compared tonormal optimum continuous operation, again, so as to avoid pluggingagain. In this way, central controller 24 simultaneously controls therate of flow of grain 14 into air system 20 while also controlling theoperation of variable frequency drive 140 to control operation of blowermotor 106.

In one arrangement, central controller 24 using processor 134 andinstructions 138 stored in memory 136 monitors the air pressure in airtube 40 for a period of time ensuring that another plug does not occurduring the initial reentry of grain 14. Central controller 24 usingprocessor 134 and instructions 138 stored in memory 136 continues toiteratively increase the amount of grain 14 added to air tube 40followed by periods of monitoring the air pressure in the air tube 40until the desired air pressure range is achieved. Simultaneously,central controller 24 is used to adjust the speed of blower motor 106using variable frequency drive 140. In this way, central controller 24continuously and in real time balances the amount of grain 14 flowinginto air tube 40 with the output of blower motor 106. In onearrangement, central controller 24 iteratively continues to increasegrain flow into air tube 40 while iteratively reducing output of blowermotor 106 until optimum equilibrium operation is achieved.

In this way, central controller 24 controls operation of air system 20having a variable frequency drive 140 to control operation of blowermotor 106 in an optimum and maximized operation while avoiding plugs.

Unplugging Routine: In one arrangement, when a plug is detected in tube40, central controller 24 may begin what is known as an unpluggingroutine.

In one arrangement, a plug is detected when the air pressure in air tube40 and/or current draw of blower motor 106 reaches point “C” on FIGS. 5and 6 respectively. If a plug occurs and an early detection routine wasperformed, as is described herein, this means the early detectionprocess was not successful in avoiding the plug.

In this arrangement, when a plug is detected in tube 40, in addition toshutting down the flow of grain 14 into tube 40, it that wasn't alreadydone, in an attempt to prevent the plug from getting worse as isdescribed herein, central controller 24 may also adjust the operation ofblower motor 106 through the variable frequency drive 140.

Thereafter, in one arrangement, as an initial step, central controller24 ramps up operation of blower motor 106 using variable frequency drive140 to full output or near full output in an effort to apply fullpressure to the plug and power the plug through tube 40. In this initialstep, the central controller 24 is essentially leaning on the plug withits full force in an attempt to move the plug and/or break it apart.This application of full force to the plug is performed either until theplug is cleared, until a predetermined amount of time passes and thecentral controller 24 determines the plug cannot be cleared by leaningon the plug, or until a fault occurs (it should be noted that in somecases it is undesirable to run the system 10 to the point where a faultoccurs as this may cause wear on parts of the system 10, and hitting afault may automatic shutting down of various components of the system 10which require later restarting, either automatically or manually, beforeoperation can continue).

In one arrangement, when a plug is detected in tube 40, that cannot becleared by ramping up output of blower motor 106, central controller 24may begin what is known as an unplugging routine. That is, when centralcontroller 24 detects a plug has occurred, central controller 24immediately shuts down the additional flow of grain 14 into tube 40, ifthat wasn't already done already. Thereafter, central controller 24 inconcert with variable frequency drive 140 attempts to self-clear theplug in tube 40 by ramping up operation of blower motor 106 to full oralmost full capacity for a predetermined or calculated amount of time.In doing so, the plug is exposed to increased or maximum air pressure,which has a tendency to clear the plug. Thereafter, if the plug is notcleared, central controller 24 in concert with variable frequency drive140, ramps down the operation of blower motor 106 thereby reducing theoutput of blower motor 106 and reducing the air pressure experienced bythe plug for a predetermined amount of time or a calculated amount oftime. Thereafter, if the plug is not cleared, central controller 24 inconcert with variable frequency drive 140 again ramps up operation ofblower motor 106 to full or almost full capacity for a predetermined orcalculated amount of time. Again, exposing the plug to increased ormaximum air pressure, which has a tendency to clear the plug.

In this way, using central controller 24 in concert with variablefrequency drive 140 to ramp up and ramp down operation of blower motor106 this causes a pulsing flow of air pressure to flow through tube 40.When these iterative pulses impact the plug in tube 40 these pulses havea tendency to either break the plug apart and return it to flowingmaterial, or alternatively these pulses have a tendency to bump the plugalong the length of tube 40 until the plug clears the end of tube 40 andis deposited into dry grain bin 22.

In one arrangement, central controller 24 is configured to continue thisiterative pulsing of the unplugging routine in an attempt to clear theplug for a predetermined amount of time. If central controller 24 iscapable of automatically clearing the plug in tube 40 the centralcontroller 24 resumes normal operation of the system 10 such asre-introducing the flow of grain 14 into tube 40, restarting grain dryer18 and all the associated systems and motors therein, restarting inputdevice 16 and the like. Notably, in this arrangement, with the use ofvariable frequency drive 140, when the plug is cleared, centralcontroller 24 resumes normal operation by reducing the output of blowermotor 106 using variable frequency drive 140 to the desired level of airpressure within tube 40.

As such, in this arrangement, central controller 24 automaticallydetected a plug in tube 40, automatically shut down components of thesystem 10 to stop the flow of grain 14 into tube 40 to prevent the plugfrom getting worse, automatically entered into an unplugging routine,automatically cleared the plug, automatically detected the plug wascleared, and then automatically restarted normal operation of the system10. This is all without user intervention. This is also withoutjeopardizing damage to components of the system 10.

In the event that after a predetermined number of attempts or acalculated amount of attempts at pulsing or bumping the plug in tube 40,central controller 24 determines it is not capable of clearing the plugin tube 40, central controller 24 shuts down operation of blower motor106 so as to preserve blower motor 106 and to preserve energy. Inconcert with determining that the plug in tube 40 cannot beautomatically cleared, a fault message is transmitted by centralcontroller 24 through the internet 26, the cloud 28 and/or wirelessnetwork 30 to a user's electronic device 32 such as their desktop orlaptop computer 34, their cell phone 36, their tablet 38 and/or anyother device in the form of a text message, a voice message, an email,an alert, or any other message thereby informing them that a plug hasoccurred and operation of the system 10 has been shut down.

The resulting effect on PSI of this unplugging routine using variablefrequency drive 140 may be similar to the graph shown in FIG. 9 ,however it is contemplated that the effect on air pressure when usingvariable frequency drive 140 to ramp up and ramp down blower motor 106may be attenuated or smoother or slower than when compared to usingdynamic pressure relief valve 114 due to the amount of time it may taketo ramp up and ramp down blower motor 106 and the inability todynamically and automatically bleed air pressure from tube 40.

This graph of FIG. 9 is only one of countless examples of an unpluggingroutine and is intended only to be demonstrative in nature. The shape ofthis graph may change dramatically by the manner in which blower motor106 is operated by central controller 24 in concert with variablefrequency drive 140.

It is worthwhile to note, that in this arrangement, system 10 does nothave a dynamic pressure relief valve 114 and therefore the centralcontroller 24 is unable selectively bleed air pressure from tube 40. Assuch, the unplugging routine is performed essentially exclusivelythrough the operation of blower motor 106 through central controller 24and variable frequency drive 140.

In Operation—System with Variable Frequency Drive and Dynamic PressureRelief Valve:

In this example of operating grain handling system 10, grain handlingsystem 10 includes an input device 16, a grain dryer 18, an air system20 and a variable frequency drive 140 and a dynamic pressure reliefvalve 114. In this example, with the addition of a variable frequencydrive 140 as well as dynamic pressure relief valve 114, all of theoperational teachings presented above with respect to a system 10 only adynamic pressure relief valve 114, only a variable frequency drive 140,as well as with respect to a system 10 without either a dynamic pressurerelief valve 114 or a variable frequency drive 140 apply with the addedability to adjust the speed of blower motor 106 using variable frequencydrive 140 as well as adjust the position of the dynamic pressure reliefvalve 114. That is, all prior teaching herein is incorporated into andapplicable to this example as well as the further teaching presentedbelow.

It is counterintuitive to provide a grain handling system 10 having botha dynamic pressure relief valve 114 as well as a variable frequencydrive 140. This is because, both the dynamic pressure relief valve 114as well as a variable frequency drive 140 are configured to provide thesame result, that is, to reduce air pressure within tube 40 to a desiredlevel. However, these two devices accomplish this same result incompletely different ways.

That is, the use of a variable frequency drive 140 is essentially a moreelegant solution. The variable frequency drive 140 is moresophisticated, more expensive initially and increases complexity of thesystem 10. However, the use of variable frequency drive 140 allows forprecise control of blower motor 106 such that the blower motor 106provides the exact desired air pressure through tube 40, not more andnot less. In doing so, the use of variable frequency drive 140 reducesthe operating cost of system 10 by reducing the power consumed by blowermotor 106 to only that which is truly needed. The use of a variablefrequency drive 140 can also reduce the wear and tear on blower motor106 and increase the longevity of the system 10.

In contrast, the use of a dynamic pressure relief valve 114 isessentially a crude or rough but highly effective solution. In thisarrangement, the blower motor 106 is essentially continuously operatedat maximum or near maximum capacity and then dynamic pressure reliefvalve 114 is used to bleed off any extra air pressure or air flow. Thiscauses the consumption of excess energy by blower motor 106 (which isessentially bled-off) and can cause excess wear and tear on blower motor106 and other components of the system 10. However, the use of dynamicpressure relief valve 114 is highly effective and robust, albeit crude.In addition, the use of dynamic pressure relief valve 114 is initiallyless expensive than using a variable frequency drive 140.

As variable frequency drive 140 and dynamic pressure relief valve 114essentially perform the same function there is essentially no reason toassembly a grain handling system 10 that includes both variablefrequency drive 140 and dynamic pressure relief valve 114. To do sowould excessively and unnecessarily increase cost and complexity of theresulting grain handling system 10 without providing any functionaladvantages.

However, in this example, the combination of variable frequency drive140 and dynamic pressure relief valve 114 in a single grain handlingsystem 10 provides the benefits of running the blower motor 106 at areduced output during normal operation. During normal operation,essentially dynamic pressure relief valve 114 is not used.

Early Detection: As is described herein, when a plug is detected, orearly detection indicates that a plug may be forming, central controller24 stops the flow of grain 14 into tube 40 to prevent the plug fromgetting worse, and central controller 24 through the use of variablefrequency drive 140 ramps up operation of blower motor 106 to full ornear full output while ensuring that dynamic pressure relief valve 114is closed.

By ramping up operation of blower motor 106 and ensuring dynamicpressure relief valve 114 is closed upon the early detection of a plug,central controller 24 ensures that full power of blower motor 106 isapplied to clearing the potential plug in the air tube 40 or preventingthe potential plug from forming into an actual plug. This has thetendency to reduce the potential for a plug to occur and fault limit “F”to be hit at point “C”.

If the potential plug clears, and the air pressure drops in responsethereto, central controller 24 using processor 134 and instructions 138stored in memory 136 detects this drop in air pressure and again seeksto control the system 10 to optimum equilibrium operation again. This isaccomplished again by automatically reinitiating the flow of grain intoair tube 40. In doing so, central controller 24 using processor 134 andinstructions 138 stored in memory 136 in an attempt to avoid anotherplug central controller 24 starts metering grain 14 into air tube 40 ata slow or slower initial rate. Simultaneously, central controller 24using processor 134 and instructions 138 stored in memory 136 controlsoperation of variable frequency drive 140 to control operation of blowermotor 106 as well as dynamic pressure relief valve 114. In doing so,central controller 24 using processor 134 and instructions 138 stored inmemory 136 in an attempt to avoid another plug central controller 24initially maintains operation of blower motor 106 at an elevated outputor slightly elevated output as compared to normal optimum continuousoperation. During this time, in one arrangement, central controller 24controls dynamic pressure relief valve 114 to remain closed. This is soas to avoid plugging again. In this way, central controller 24simultaneously controls the rate of flow of grain 14 into air system 20while also controlling the operation of variable frequency drive 140 tocontrol operation of blower motor 106 as well as dynamic pressure reliefvalve 114.

In one arrangement, central controller 24 using processor 134 andinstructions 138 stored in memory 136 monitors the air pressure in airtube 40 for a period of time ensuring that another plug does not occurduring the initial reentry of grain 14. Central controller 24 usingprocessor 134 and instructions 138 stored in memory 136 continues toiteratively increase the amount of grain 14 added to air tube 40followed by periods of monitoring the air pressure in the air tube 40until the desired air pressure range is achieved. Simultaneously,central controller 24 is used to adjust the speed of blower motor 106using variable frequency drive 140 and/or adjust the position of dynamicpressure relief valve 114. In this way, central controller 24continuously and in real time balances the amount of grain 14 flowinginto air tube 40 with the output of blower motor 106 as well as theposition of dynamic pressure relief valve 114. In one arrangement,central controller 24 iteratively continues to increase grain flow intoair tube 40 while iteratively reducing output of blower motor 106 untiloptimum equilibrium operation is achieved while maintaining dynamicpressure relief valve 114 in a closed position.

In this way, central controller 24 controls operation of air system 20having a variable frequency drive 140 to control operation of blowermotor 106 in an optimum and maximized operation while avoiding plugswhile maintaining dynamic pressure relief valve 114 in a closedposition.

Unplugging Routine: In one arrangement, when a plug is detected in tube40, central controller 24 may begin what is known as an unpluggingroutine.

Then, when a plug is detected, variable frequency drive 140 is used toramp up the output of blower motor 106 to provide maximum power, maximumair flow and maximum air pressure. Then, when a plug is detected, andthe blower motor 106 has been ramped up to full capacity or near fullcapacity by central controller 24 using variable frequency drive 140,dynamic pressure relief valve 114 and actuator 118 is used to perform anunplugging routine, as is described herein. That is, dynamic pressurerelief valve 114 and actuator 118 is used oscillate valve body 116between a fully open position and a fully closed (or any position therebetween) as is described herein. This causes pulses of air flow toimpact the plug either breaking the plug apart or bumping the plug alongtube 40 until it clears as is described herein.

Once the plug is cleared, central controller 24 resumes normal operationby closing dynamic pressure relief valve 114 and controlling the outputof blower motor 106 using variable frequency drive 140 to the precisedesired output which obviates the need for venting through dynamicpressure relief valve 114.

In this way, the combination of central controller 24, sensors 120, 122,144, 146,148 and 150 (among others) dynamic pressure relief valve 114and actuator 118 are used to provide new and never before availablefunctionality of automatically detecting and clearing a plug in an airsystem 20 while operating the air system 20 with optimum efficiencyduring normal operation.

Notice to User:

In one arrangement, when an early detection routine occurs, and/or anunplugging routine occurs, notice is sent to a user by centralcontroller 24 by sending a message to the user's electronic device 32.

Static v. Dynamic Rotary Air Valve & Surge Bin:

Static Operation: In one arrangement, rotary airlock 124 operates at agenerally constant speed. That is, the motor of rotary air lock 124operates in a generally binary manner, either on or off, operating ornot-operating, and/or the speed at which the vanes within rotary airlock124 rotate at a generally constant equilibrium speed. In onearrangement, central controller 24 controls this binary operation ofrotary air lock 124. In this arrangement, the amount of grain 14 thatenters air system 20 is varied by a varying operation of a mechanismthat inputs grain 14 into airlock 124 such as a gate 156 in or alonginput tube 158 and/or surge bin 160 which facilitates the flow of grain14 into rotary airlock 124, and/or by varying operation of the dischargesystem 82 of grain dryer 18 and/or metering system 80 of grain dryer 18,and/or by varying operation of any other component of the system thatfacilities the flow of grain 14 to rotary airlock 124 and/or air system20. In this arrangement, rotary airlock 124 operates at a relativelyconstant, maximum, and/or equilibrium speed while the input of grain 14into rotary airlock 124 is varied by central controller 24 to providethe optimum amount of grain 14 at any given moment depending upon theoperational characteristics of the system 10 at that time.

Dynamic Operation: In an alternative arrangement, the speed at whichrotary airlock 124 operates is dynamic in nature. That is, the motor ofrotary air lock 124 operates in a generally variable and/or dynamicmanner, meaning it may be sped up or slowed down, and/or the speed atwhich the vanes within rotary airlock 124 rotate at a variable speed. Inone arrangement, central controller 24 controls this variable operationof rotary air lock 124. In this arrangement, the amount of grain 14 thatenters air system 20 may be varied by varying operation of the rotaryairlock 124. Further variance may also be achieved by also varyingoperation of a mechanism that inputs grain 14 into airlock 124 such as agate 156 in or along input tube 158 and/or surge bin 160 whichfacilitates the flow of grain 14 into rotary airlock 124, and/or byvarying operation of the discharge system 82 of grain dryer 18 and/ormetering system 80 of grain dryer 18, and/or by varying operation of anyother component of the system that facilities the flow of grain 14 torotary airlock 124 and/or air system 20. In this arrangement, rotaryairlock 124 may operate at a variable speed. When the input side ofrotary airlock 124 is full with grain 14, to increase the flow of grain14 into air system 20 operation of the rotary airlock 124 is sped up bycentral controller 24. When the input side of rotary airlock 124 is fullwith grain 14, to reduce the flow of grain 14 into air system 20operation of the rotary airlock 124 is slowed down by centralcontroller. In this way, a dynamic rotary airlock 124 is controlled bycentral controller 24 to provide the optimum amount of grain 14 at anygiven moment depending upon the operational characteristics of thesystem 10. Further variance may also be achieved by central controller24 varying the flow of grain 14 to rotary airlock 124 by dynamicallycontrolling operation of an input mechanism.

Surge Bin: In one arrangement, a surge bin 160 is placed upstream ofrotary airlock 124. Surge bin 160 is formed of any suitable size, shapeand design and is configured to receive and temporarily hold an amountof grain 14 which is to be supplied to rotary airlock 124. The in thearrangement shown, in FIG. 1 , surge bin 160 is placed between graindryer 18 and rotary airlock 124. This placement provides someflexibility and give in the operation of system 10 as surge bin 160receives grain 14 coming out of grain dryer 18, temporarily holds thisgrain 14, and then provides this grain 14 on demand to rotary airlock124. This temporary grain storage between rotary airlock 124 and graindryer 18 allows for smoother equilibrium operation of grain dryer 18 aswell as air system 20.

That is, during operation of system 10, grain 14 flowing out of graindryer 18 is temporarily held in surge bin 160. This grain 14 is drawnout of surge bin 160 by operation of a metering system, gate or otherdevice that controls the outflow of grain 14 from surge bin 18, such asgate 156. When grain dryer 18 is discharging grain 14 faster than airsystem 20 can consume the grain 14, grain 14 piles up in surge bin 160.When air system 20 is consuming grain 14 faster than grain dryer 18 isdischarging grain 14, grain 14 is drained from surge bin 160.

The amount of grain 14 held in surge bin 160 is sensed by sensors 162.This information is transmitted to central controller 24. Centralcontroller 24 controls the operational characteristics of grain dryer 18as well as air system 20 based on this information, as well as otherinputs of the system 10. Based on this information, central controller24 may smoothly and proactively control operation of the grain dryer 18,air system 20 and other components of the system 10 in a more-constantand equilibrium manner which reduces the need to shut down components ofthe system 10.

That is, when a plug is detected in air tube 40, central controller 24may close gate 156 thereby stopping the flow of grain 14 into rotaryairlock 124. When this occurs, grain 14 piles up within surge bin 162while the central controller 24 attempts to clear the plug. If the surgebin 160 fills before the plug is cleared, a limit switch is triggeredand/or a sensor 162 is triggered and the flow of grain 14 into the surgebin 160 is stopped, such as by shutting down operation of the graindryer 18. However, this is undesirable as this requires restarting thegrain dryer 18 and inevitably requires reestablishing equilibrium ofoperation of the grain dryer 18 once the plug is cleared.

In contrast, if the plug is cleared before the surge bin 160 fills, thecentral controller 24 reinitiates the flow of grain 14 into the rotaryairlock 124 once the plug is cleared. This allows continued anduninterrupted operation of the grain dryer 18 despite stopping the flowof grain 18 into the air system 20. In this arrangement, the presence ofan on demand inventory of grain 14, and storage of grain 14, at theinput of rotary airlock 124 and output of grain dryer 18 reduces theneed to stop operation of the grain dryer 18 when operational changesoccur to the air system 20.

Also, when changes occur to the operational characteristic of air system20, the presence of an on demand inventory of grain 14, and storage ofgrain 14, at the input of rotary airlock 124 and output of grain dryer18 gives central controller 24 time to adjust the operationalcharacteristics of grain dryer 18 and/or air system 20, and/or othercomponents of the system 10 to help seek a new equilibrium. That is,this on demand inventory of grain 14, and storage of grain 14, at theinput of rotary airlock 124 and output of grain dryer 18 gives centralcontroller 24 time to slowly and smoothly adjust operation of the entiresystem 10 to seek a new equilibrium. This avoids the need to abruptlyreact and shutdown components of the system 10, which is an improvementover the prior art.

From the above discussion it will be appreciated that the air system andmethod of control presented herein improves upon the state of the artand that some, if not all, of the objectives have been met.

Specifically, the air system and method of control presented herein:reduces plugging of the air system; automatically detects plugging ofthe air system; automatically clears plugs in the air system;automatically detects plugs in the air system; automatically shuts downthe flow of grain into the air system when a plug is detected; minimizesa plug in the air system when the plug is detected; is capable ofclearing a plug and resuming normal operation automatically and withoutmanual intervention; that is more robust than existing air systems; thatreduces the cost of operating air systems; that reduces the laborrelated to operating air systems; that makes air systems more desirable;that optimally controls operation of the air system; that reduces thepotential for catastrophic occurrences; that increases the up-time ofair systems; that reduces the down-time of air systems; provides newfunctionality for air systems; improves the safety of using air systems;is easy to use; has a robust design; works effectively; saves time; isefficient to use; has a long useful life; protects the quality of thegrain; is durable; is relatively inexpensive; is high quality; can beused with practically any grain handling system; and makes it easier tohandle grain, among countless other advantages and improvements.

It will be appreciated by those skilled in the art that other variousmodifications could be made to the device without parting from thespirit and scope of this disclosure. All such modifications and changesfall within the scope of the claims and are intended to be coveredthereby.

What is claimed:
 1. A grain handling system, comprising: a tube; asource of grain; the source of grain operatively connected to the tubeand configured to provide grain to the tube; a blower motor; the blowermotor operatively connected to the tube and configured to providepressurized air to the tube and thereby cause grain to be transportedthrough the tube by air movement through the tube; a variable frequencydrive; the variable frequency drive operatively connected to the blowermotor and configured to control operation of the blower motor; apressure relief valve; the pressure relief valve operatively connectedto the tube and configured to bleed air pressure from the tube; anactuator; the actuator operatively connected to the pressure reliefvalve and configured to control operation of the pressure relief valve;a first sensor; the first sensor operatively connected to the grainhandling system and configured to sense operational characteristics ofthe grain handling system; a central controller; the central controlleroperatively connected to the variable frequency drive of the blowermotor, the actuator of the pressure relief valve and the first sensor;wherein when the central controller detects that a plug has occurred thecentral controller is configured to automatically begin an unpluggingroutine; wherein the central controller is configured to detect when aplug in the tube has occurred; wherein the unplugging routine includesramping up the output of the blower motor using the variable frequencydrive while moving the pressure relief valve between an open positionand a closed position using the actuator thereby causing surges in airpressure in the tube.
 2. The system of claim 1, wherein the first sensoris a pressure sensor operatively connected to the tube and configured tosense air pressure in the tube.
 3. The system of claim 1, wherein thefirst sensor is a pressure sensor operatively connected to the tube andconfigured to sense air pressure in the tube; and a second sensor;wherein the second sensor is a current sensor operatively connected tothe blower motor and configured to sense current draw of the blowermotor.
 4. The system of claim 1, wherein the pressure relief valve isinfinitely movable between a fully open position and a fully closedposition.
 5. The system of claim 1, wherein the central controller isconfigured to detect when a plug in the tube has occurred by an increasein air pressure in the tube.
 6. The system of claim 1, wherein when thecentral controller detects when a plug has occurred the centralcontroller is configured to stop the flow of grain into the tube fromthe source of grain.
 7. The system of claim 1, wherein the pressurerelief valve is an electronically controlled dynamic pressure reliefvalve.
 8. The system of claim 1, further comprising a manual pressurerelief valve operatively connected to the tube.
 9. A method ofcontrolling a grain handling system, the steps comprising: providing ablower motor, a variable frequency drive operatively connected to theblower motor, a pressure relief valve, an actuator operatively connectedto the pressure relief valve, a first sensor, and a central controlleroperatively connected to the variable frequency drive of the blowermotor, the actuator of the pressure relief valve and the first sensor;blowing pressurized air into a tube by the blower motor; providing graininto the tube from a source of grain; transporting grain through thetube by air movement through the tube; detecting when a plug hasoccurred in the tube by the central controller; initiating an unpluggingroutine by the central controller in response to detecting a plug hasoccurred by ramping up output of the blower motor using the variablefrequency drive while moving the pressure relief valve between an openposition and a closed position using the actuator thereby causing surgesin air pressure in the tube.
 10. The method of claim 9, furthercomprising the step of stopping the flow of grain into the tube by thecentral controller in response to detecting a plug has occurred.
 11. Themethod of claim 9, further comprising the step of detecting when theplug has cleared and in response resuming normal operation.
 12. Themethod of claim 9, further comprising the step of detecting when theplug has cleared and in response optimizing output of the blower motorusing the variable frequency drive.
 13. The method of claim 9, furthercomprising the step of detecting when the plug has cleared and inresponse reducing output of the blower motor to an optimum level usingthe variable frequency drive.
 14. The method of claim 9, furthercomprising the step of detecting when the plug has cleared and inresponse reinitiating the flow of grain into the tube by the centralcontroller.
 15. The method of claim 9, wherein ramping up output of theblower motor includes operating the blower motor at full power.
 16. Themethod of claim 9, wherein the first sensor is a pressure sensor. 17.The method of claim 9, wherein the first sensor is a pressure sensoroperatively connected to the tube and configured to sense air pressurein the tube.
 18. The method of claim 9, wherein the first sensor is apressure sensor operatively connected to the tube and configured tosense air pressure in the tube; and a second sensor; wherein the secondsensor is a current sensor operatively connected to the blower motor andconfigured to sense current draw of the blower motor.
 19. The method ofclaim 9, wherein the pressure relief valve is infinitely movable betweena fully open position and a fully closed position.
 20. The method ofclaim 9, wherein the central controller is configured to detect when aplug in the tube has occurred by an increase in air pressure in thetube.
 21. A method of controlling a grain handling system, the stepscomprising: detecting when a plug has occurred in a tube of an airsystem by a central controller; initiating an unplugging routine by thecentral controller in response to detecting a plug has occurred; whereinthe unplugging routine causes surges in air pressure in the tube byramping up the output of a blower motor using a variable frequency drivewhile repeating movement of a pressure relief valve between an openposition and a closed position using an actuator.
 22. The method ofclaim 21, further comprising the step of stopping the flow of grain intothe tube by the central controller in response to detecting a plug hasoccurred.
 23. The method of claim 21, further comprising the step ofresuming normal operation in response to detecting when the plug hascleared.
 24. The method of claim 21, further comprising the step ofoptimizing output of the blower motor using the variable frequency drivein response to detecting when the plug has cleared.
 25. The method ofclaim 21, further comprising the step of reducing output of the blowermotor to an optimum level using the variable frequency drive in responseto detecting when the plug has cleared.
 26. The method of claim 21,further comprising the step of reinitiating the flow of grain into thetube by the central controller in response to detecting when the plughas cleared.
 27. The method of claim 21, wherein ramping up output ofthe blower motor includes operating the blower motor at full power. 28.The method of claim 21, wherein the central controller is configured todetect when a plug in the tube has occurred by an increase in airpressure in the tube.
 29. The method of claim 21, wherein the centralcontroller detects when a plug occurs by a spike in air pressure in thetube which is sensed by a pressure sensor operatively connected to thetube and operatively connected to the central controller.
 30. The methodof claim 21, further comprising a pressure sensor operatively connectedto the tube and configured to sense air pressure in the tube.
 31. Themethod of claim 21, further comprising a pressure sensor operativelyconnected to the tube and configured to sense air pressure in the tubeand a current sensor operatively connected to the blower motor andconfigured to sense current draw of the blower motor.
 32. The method ofclaim 21, wherein the pressure relief valve is infinitely movablebetween a fully open position and a fully closed position.
 33. A methodof controlling a grain handling system, the steps comprising: detectingwhen a plug has occurred in a tube of an air system by a centralcontroller; initiating an unplugging routine by the central controllerin response to detecting a plug has occurred; wherein the unpluggingroutine causes surges in air pressure in the tube by ramping up theoutput of a blower motor using a variable frequency drive while openingand closing a pressure relief valve using an actuator until the plug hascleared.
 34. A grain handling system, comprising: a tube means fortransporting grain; a means for blowing pressurized air into a tube by ablower motor; a means for providing grain into the tube from a source ofgrain and thereby causing grain to be transported through the tube byair movement through the tube; a means for detecting when a plug hasoccurred in the tube by a central controller; a means for initiating anunplugging routine by the central controller in response to detecting aplug has occurred by ramping up output of the blower motor using avariable frequency drive while moving a pressure relief valve between anopen position and a closed position using an actuator thereby causingsurges in air pressure in the tube.